Dodge Durango (DN). Manual — part 196

(3) Disconnect the refrigerant line fitting that

secures the discharge line to the condenser inlet (Fig.
37). Install plugs in, or tape over all of the opened
refrigerant line fittings.

(4) Disconnect the refrigerant line fitting that

secures the liquid line to the condenser outlet. Install
plugs in, or tape over all of the opened refrigerant
line fittings.

(5) Remove the two screws that secure the radiator

and fan shroud module to the inside of the upper
radiator crossmember.

(6) On models equipped with a V-8 engine, remove

the radiator from the engine compartment. Refer to
Cooling Systems for the procedures.

(7) Remove the two screws that secure the con-

denser to the outside of the upper radiator cross-
member (Fig. 38).

(8) Tilt the top of the radiator and fan shroud

module towards the engine, using care not to damage
the radiator fins on the engine cooling fan.

(9) With the radiator and fan shroud module

tilted, carefully lift the condenser upwards until the
lower condenser mounts are clear of the isolators in
the lower crossmember.

(10) Remove the condenser from the vehicle.

INSTALLATION

(1) With the radiator and fan shroud module tilted

towards the engine, carefully position the lower con-
denser mounts in the lower crossmember isolators.

(2) Reinstall the two screws that secure the con-

denser to the outside of the upper radiator cross-
member and tighten to 10.7 N·m (95 in. lbs.).

(3) On models equipped with a V-8 engine, rein-

stall the radiator to the engine compartment. Refer
to Cooling Systems for the procedures.

(4) Reinstall the two screws that secure the radia-

tor and fan shroud module to the inside of the upper
radiator crossmember.

(5) Remove the plugs or tape from the refrigerant

line fittings on the liquid line and the condenser out-
let. Connect the liquid line to the condenser outlet.
Tighten the fitting to 25.99

63.39 N·m (230 630 in.

lbs.).

(6) Remove the plugs or tape from the refrigerant

line fittings on the discharge line and the condenser
inlet. Connect the discharge line to the condenser
inlet. Tighten the fitting to 25.99

63.39 N·m (230

630 in. lbs.).

(7) Check that all of the condenser and radiator

air seals are in their proper locations.

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

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

(10) Charge the refrigerant system. See Refriger-

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

Fig. 37 Condenser Line Fittings

1 – DISCHARGE LINE
2 – CONDENSOR
3 – TO LIQUID LINE

Fig. 38 Condenser Remove/Install - Typical

1 – UPPER CROSSMEMBER
2 – LOWER CROSSMEMBER
3 – CONDENSER
4 – SCREW

24 - 42

HEATING AND AIR CONDITIONING

DN

REMOVAL AND INSTALLATION (Continued)

NOTE: If the condenser 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.

DUCTS AND OUTLETS

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.

PANEL AND DEFROSTER DUCTS

The panel and defroster ducts are integral to the

instrument panel assembly. The defroster outlets are
integral to the instrument panel top cover. Refer to
Instrument Panel Assembly in the Removal and
Installation section of Group 8E - Instrument Panel
Systems for the service procedures.

OUTLET BARRELS

In addition to the panel outlet barrels in the

instrument panel, models equipped with the bucket
seat option have two outlet barrels for the rear seat
passengers located near the top of upper rear panel
of the center floor console. The service procedures for
all of these outlet barrels is the same. Models with
the optional rear overhead A/C unit also have four
outlet barrels located in the outlet bezel on the head-
liner, but these outlet barrels are only serviced as a
unit with the rear overhead A/C outlet bezel.

(1) Using a trim stick or another suitable wide-

bladed flat tool, gently pry at the sides of the outlet
barrels to release the snap-fit pivots on the barrel
from the pivot pins in the outlet housing of the
instrument panel top cover, the instrument cluster
bezel or the center floor console (Fig. 39).

(2) To install the outlet barrel, position the barrel

in the outlet housing and press inwards firmly and
evenly until the barrel snaps into place.

FRONT SEAT FLOOR DUCT

(1) Remove the three screws that secure the floor

duct to the bottom of the heater-A/C housing (Fig.
40).

(2) Remove the floor duct from the heater-A/C

housing.

(3) Reverse the removal procedures to install.

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

Fig. 39 Outlet Barrels

1 – DEMISTER OUTLETS
2 – PANEL OUTLETS

Fig. 40 Front Seat Floor Duct Remove/Install

(Typical)

1 – SCREWS
2 – FLOOR DUCT
3 – HEATER-A/C HOUSING

DN

HEATING AND AIR CONDITIONING

24 - 43

REMOVAL AND INSTALLATION (Continued)

REAR SEAT FLOOR DUCT CONTROL

SPLIT BENCH SEAT

(1) Remove the three retainers that secure the

HVAC rear bezel to the brackets near the back of the
front seat center section (Fig. 41).

(2) Pull the bezel away from the back of the front

seat far enough to access and disengage the control
cable retainer and cable end from the control.

(3) Reverse the removal procedures to install.

BUCKET SEAT

The rear floor duct control and linkage are only

serviced as a unit with the console duct assembly.

(1) Remove the four screws that secure the console

bin and remove the bin from the floor console (Fig.
42).

(2) Reach through the top of the console to disen-

gage the control rod end from the floor duct damper
door pivot.

(3) Remove the floor console from the vehicle and

disassemble as required to remove the console duct
and control assembly from the console as a unit.
Refer to Group 23 - Body for the procedures.

(4) Reverse the removal procedures to install.

REAR SEAT FLOOR DUCT

The rear seat floor duct damper door is only ser-

viced as part of the rear seat floor duct on bench seat
models, or the center seat floor duct on bucket seat
models.

(1) Remove the carpeting from the floor panel

transmission tunnel. Refer to Group 23 - Body for the
procedures.

(2) Remove the retainers that secure the ducts to

the floor panel transmission tunnel (Fig. 43) or (Fig.
44).

(3) Remove the duct(s) from the floor panel as

required.

(4) Reverse the removal procedures to install.

DEMISTER DUCT ADAPTER

(1) Roll the instrument panel assembly down, but

do not remove it from the vehicle. Refer to Instru-
ment Panel Assembly in the Removal and Installa-
tion section of Group 8E - Instrument Panel Systems
for the procedures.

(2) Disconnect the flexible demister duct hose from

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

Fig. 41 Rear Seat Floor Duct Control - Split Bench Seat

1 – KNOB
2 – CONTROL
3 – BEZEL
4 – RETAINER
5 – FRONT SEAT BRACKETS

6 – CABLE
7 – DUCT
8 – DIFFUSER
9 – RETAINER

24 - 44

HEATING AND AIR CONDITIONING

DN

REMOVAL AND INSTALLATION (Continued)

(3) Remove the two screws that secure the demis-

ter duct adapter to the top of the heater-A/C housing
(Fig. 45).

(4) Remove the demister duct adapter from the

heater-A/C housing.

(5) Reverse the removal procedures to install.

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

DEMISTER HOSE

(1) Remove the heater-A/C control from the instru-

ment panel. See Heater-A/C Control in the Removal
and Installation section of this group for the proce-
dures.

(2) Reach through the heater-A/C control opening

in the instrument panel to access and remove the
screw that secures the flexible demister duct hose to
the demister duct tee.

(3) Roll the instrument panel assembly down, but

do not remove it from the vehicle. Refer to Instru-
ment Panel Assembly in the Removal and Installa-
tion section of Group 8E - Instrument Panel Systems
for the procedures.

Fig. 42 Rear Seat Floor Duct Control - Bucket Seat

1 – SCREW
2 – SCREW
3 – UPPER REAR PANEL
4 – LOWER REAR PANEL
5 – CONTROL ROD END

6 – DAMPER DOOR PIVOT
7 – BASE PLATE
8 – FLOOR CONSOLE
9 – BIN

Fig. 43 Rear Seat Floor Ducts Remove/Install - Split

Bench Seat

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

DN

HEATING AND AIR CONDITIONING

24 - 45

REMOVAL AND INSTALLATION (Continued)