Dodge Durango (DN). Manual — part 198

INSTALLATION

(1) Position the rear evaporator coil to the rear

overhead A/C unit and secure with two mounting
screws. Tighten the mounting screws to 2.2 N·m (20
in. lbs.).

(2) Install the rear overhead A/C refrigerant tube

and block fitting retaining strap to the right side of
the upper housing cover and secure with a screw.
Tighten the mounting screws to 2.2 N·m (20 in. lbs.).

(3) 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 positioning the cover to the unit.

(4) Be certain that the lower housing cover snap

retainer near the center of the outlet side (rear) of
the rear overhead A/C unit is engaged.

(5) Install the nine screws that secure the lower

housing cover to the rear overhead A/C unit. Tighten
the mounting screws to 2.2 N·m (20 in. lbs.).

(6) Connect the B-pillar drain hoses to the wye fit-

tings on each side of the rear overhead A/C unit.

(7) Remove the tape or plugs from block fittings at

the top of the B-pillar refrigerant line unit, and from
the fittings on the rear overhead A/C unit. Install the
B-pillar refrigerant line block fittings over the two
studs on the rear overhead A/C unit and secure the
connections with the mounting nuts. Tighten the
mounting nuts to 11.3 N·m (100 in. lbs.).

(8) Reinstall the headliner in the passenger com-

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

(9) Connect the battery negative cable.
(10) Evacuate the refrigerant system. See Refriger-

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

(11) Charge the refrigerant system. See Refriger-

ant System Charge in the Service Procedures section
of this group.

NOTE: If the rear evaporator coil and expansion
valve unit is replaced, add 30 milliliters (1 fluid
ounce) of refrigerant oil to the refrigerant system.
Use only refrigerant oil of the type recommended
for the compressor in the vehicle.

Fig. 53 Rear Overhead A/C Unit Lower Housing

Cover Remove/Install

1 – REAR OVERHEAD A/C UNIT LOWER HOUSING COVER
2 – SNAP RETAINER
3 – OUTLET SIDE
4 – BLOWER MOTOR SWITCH WIRE HARNESS CONNECTOR
5 – INLET SIDE
6 – DRAIN HOSES

Fig. 54 Rear A/C Tube Retaining Strap Remove/

Install

1 – BLOWER WHEEL
2 – RETAINING STRAP
3 – SCREW
4 – EVAPORATOR COIL

Fig. 55 Rear Evaporator Coil Remove/Install

1 – BLOWER WHEEL AND HOUSING
2 – SCREWS
3 – EVAPORATOR COIL

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HEATING AND AIR CONDITIONING

DN

REMOVAL AND INSTALLATION (Continued)

EXPANSION VALVE

FRONT

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

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 rear liquid line from the engine

compartment. See Liquid Line in the Removal and
Installation section of this group for the procedures.

(4) Remove the electronic cycling clutch switch

from the outboard side of the expansion valve. See
Electronic Cycling Clutch Switch in the Removal and
Installation section of this group for the procedures.

(5) Remove the two screws that secure the expan-

sion valve to the evaporator tube mounting flange
(Fig. 56).

(6) Remove the expansion valve from the evapora-

tor tube mounting flange. Install plugs in, or tape
over all of the opened refrigerant line fittings.

INSTALLATION

(1) Remove the tape or plugs from the evaporator

tubes and the evaporator tube mounting flange side

of the expansion valve. Install the expansion valve to
the evaporator tube mounting flange and secure with
two screws. Tighten the mounting screws to 11.4 N·m
(100 in. lbs.).

(2) Reinstall the electronic cycling clutch switch to

the outboard side of the expansion valve. See Elec-
tronic Cycling Clutch Switch in the Removal and
Installation section of this group for the procedures.

(3) Reinstall the rear liquid line to the engine com-

partment. See Liquid Line in the Removal and
Installation section of this group for the procedures.

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

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

(6) Charge the refrigerant system. See Refrigerant

System Charge in the Service Procedures section of
this group.

REAR

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

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 engine air filter housing. Refer to

Group 14 - Fuel System for the procedures.

(4) Remove the underbody line. See Underbody

Refrigerant Line in the Removal and Installation sec-
tion of this group for the procedures. Remove the line
from the vehicle and install plugs in, or tape over, all
of the open refrigerant fittings.

(5) Disassemble the bolt (M6) from the forward

(longer) section of the underbody lines to the valve.
Install plugs in, or tape over the open refrigerant fit-
tings.

(6) Disassemble the two bolts attaching the expan-

sion valve to the rearward (shorter) section of the
underbody lines. Install plugs in, or tape over the
open refrigerant fittings.

INSTALLATION

(1) Remove the tape or plugs from expansion valve

and the rearward (shorter) section of the underbody
lines. Align the expansion valve ports with the block
fitting on the rearward lines and assemble with the
two bolts.

(2) Remove the tape or plugs from the forward

(longer) section of the underbody lines. Align the

Fig. 56 Expansion Valve Remove/Install

1 – EXPANSION VALVE
2 – EVAPORATOR TUBE MOUNTING FLANGE
3 – SCREW

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HEATING AND AIR CONDITIONING

24 - 51

REMOVAL AND INSTALLATION (Continued)

expansion valve ports and stud with the block fitting
on the forward lines. Secure with the mounting bolt.

(3) Install the underbody refrigerant lines. See

Underbody Refrigerant Line in the Removal and
Installation section of this group.

(4) Install the engine air filter housing. Refer to

Group 14 - Fuel System for the procedures.

(5) Evacuate and charge the refrigerant system.

See Refrigerant System Evacuate in the Service Pro-
cedures section of this group.

(6) Connect the battery negative cable.

FILTER-DRIER

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

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 screws that secure the front and

rear liquid line block fittings to the filter-drier inlet

and outlet (Fig. 58). Disengage the block fittings from
the filter-drier. Install plugs in, or tape over all of the
opened refrigerant line fittings.

(4) Remove the screw that secures the filter-drier

mounting bracket to the front fender wheelhouse
front extension.

(5) Remove the filter-drier from the engine com-

partment.

INSTALLATION

(1) Position the filter-drier and its bracket to the

front fender wheelhouse front extension as a unit
and loosely secure it with the mounting screw.

(2) Remove the tape or plugs from the front liquid

line block fitting and the filter-drier inlet. Install the
front liquid line block fitting to the filter-drier inlet
and secure the connection with a screw. Tighten the
mounting screw to 13.5 N·m (120 in. lbs.).

(3) Remove the tape or plugs from the rear liquid

line block fitting and the filter-drier outlet. Install
the rear liquid line block fitting to the filter-drier
outlet and secure the connection with a screw.
Tighten the mounting screw to 13.5 N·m (120 in.
lbs.).

(4) Tighten the filter-drier bracket mounting screw

to 6.8 N·m (60 in. lbs.).

(5) Connect the battery negative cable.

Fig. 57 REAR EXPANSION VALVE REMOVAL/

INSTALL

1 – SCREW
2 – SCREW (2)
3 – REAR UNDERBODY LINE MOUNTING BLOCK
4 – REAR EXPANSION VALVE
5 – FRONT UNDERBODY LINE MOUNTING BLOCK

Fig. 58 Filter-Drier Remove/Install

1 – SCREW
2 – SCREW
3 – REAR LIQUID LINE
4 – BRACKET
5 – FILTER-DRIER
6 – FRONT LIQUID LINE

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HEATING AND AIR CONDITIONING

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REMOVAL AND INSTALLATION (Continued)

(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.

NOTE: If the filter-drier is replaced, add 30 millili-
ters (1 fluid ounce) of refrigerant oil to the refriger-
ant system. Use only refrigerant oil of the type
recommended for the compressor in the vehicle.

HEATER-A/C CONTROL

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 cluster bezel from the instrument

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

(3) Remove the four screws that secure the heater-

A/C control to the instrument panel (Fig. 59).

(4) Pull the heater-A/C control assembly away

from the instrument panel far enough to access the
connections on the back of the control.

(5) Unplug the wire harness connector from the

back of the heater-A/C control (Fig. 60).

(6) Disconnect the wire harness retainer from the

side of the heater-A/C control assembly.

(7) Remove the two stamped nuts that secure the

vacuum harness connector and unplug the connector
from the back of the heater-A/C control.

(8) Release the temperature control cable housing

flag retainer latch in the receptacle on the back of
the

heater-A/C

control

and

disengage

the

flag

retainer from the receptacle.

(9) Rotate the heater-A/C control assembly to align

the cable core with the slot on the end of the temper-
ature control lever and disengage the cable end from
the lever.

(10) Remove

the

heater-A/C

control

from

the

instrument panel.

INSTALLATION

(1) Connect the temperature control cable core end

to the temperature control lever on the back of the
heater-A/C control.

Fig. 59 Heater-A/C Control Remove/Install

1 – SCREW
2 – CONTROL

Fig. 60 Heater-A/C Control Connections

1 – WIRE HARNESS CONNECTOR
2 – VACUUM HARNESS CONNECTOR
3 – FLAG RETAINER
4 – TEMPERATURE CONTROL CABLE
5 – CONTROL

DN

HEATING AND AIR CONDITIONING

24 - 53

REMOVAL AND INSTALLATION (Continued)