Dodge Durango (DN). Manual — part 200
FLOOR-DEFROST 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) Remove the push nut retainer that secures the
floor-defrost door actuator link to the floor-defrost
door crank arm (Fig. 69).
(3) Disengage the floor-defrost door actuator link
from the floor-defrost door crank arm.
(4) Remove the floor-defrost door from the heater-
A/C housing.
(5) Reverse the removal procedures to install.
PANEL-DEFROST 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 panel-defrost door out of the heater-
A/C housing. Assure that the chute assembly on
the panel-defrost door is properly positioned.
(3) Reverse the removal procedures to install.
RECIRCULATION AIR DOOR
A recirculation air door and vacuum actuator are
used only on models with the optional air condition-
ing system.
(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) Remove the recirculation air door actuator from
the blower motor housing cover. See Mode Door Vac-
uum Actuators in the Removal and Installation sec-
tion of this group for the procedures.
Fig. 68 Blend-Air Door Remove/Install
1 – BLEND-AIR DOOR
2 – EVAPORATOR COIL
Fig. 69 Floor-Defrost Door Remove/Install
1 – PUSH-NUT
2 – ACTUATOR LINK
3 – HEATER-A/C HOUSING
4 – FLOOR-DEFROST DOOR
Fig. 70 Panel-Defrost Door Remove/Install
1 – PANEL-DEFROST DOOR
2 – HEATER CORE
24 - 58
HEATING AND AIR CONDITIONING
DN
REMOVAL AND INSTALLATION (Continued)
(3) Lift the lower end of the recirculation air door
up far enough so that the door lever is clear of the
recirculation air intake grille, then twist the door to
remove the door pivots from the pivot holes in the
blower motor housing cover (Fig. 71).
(4) Remove the recirculation air door from the
blower motor housing cover.
(5) Reverse the removal procedures to install.
HEATER CORE
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) 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 heater core out of the heater-A/C hous-
ing (Fig. 72).
INSTALLATION
(1) Insert the heater core 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.
HIGH PRESSURE CUT-OFF SWITCH
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Unplug the wire harness connector from the
high pressure cut-off switch, which is mounted to a
fitting on the discharge line between the compressor
and the condenser inlet (Fig. 73).
(3) Unscrew the high pressure cut-off switch from
the discharge line fitting.
(4) Remove the high pressure cut-off switch from
the vehicle.
(5) Remove the O-ring seal from the discharge line
fitting and discard.
INSTALLATION
(1) Lubricate a new O-ring seal with clean refrig-
erant oil and install it on the discharge line fitting.
Use only the specified O-rings as they are made of a
special material for the R-134a system. Use only
refrigerant oil of the type recommended for the com-
pressor in the vehicle.
(2) Install and tighten the high pressure cut-off
switch on the discharge line fitting.
(3) Plug the wire harness connector into the high
pressure cut-off switch.
(4) Connect the battery negative cable.
Fig. 71 Recirculation Air Door Remove/Install
1 – BLOWER MOTOR HOUSING COVER
2 – RECIRCULATION AIR DOOR
3 – DOOR PIVOT HOLES
Fig. 72 Heater Core Remove/Install
1 – HEATER-A/C HOUSING
2 – HEATER CORE
DN
HEATING AND AIR CONDITIONING
24 - 59
REMOVAL AND INSTALLATION (Continued)
LIQUID LINE
Any kinks or sharp bends in the refrigerant plumb-
ing will reduce the capacity of the entire air condi-
tioning system. Kinks and sharp bends reduce the
flow of refrigerant in the system. High pressures are
produced in the refrigerant system when the air con-
ditioning compressor is operating. Extreme care must
be exercised to make sure that each of the refriger-
ant system connections is pressure-tight and leak
free.
WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE PER-
FORMING THE FOLLOWING OPERATION.
FRONT
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 screw that secures the front liquid
line block fitting to the inlet of the filter-drier, and
disengage the fitting from the filter-drier (Fig. 74).
Install plugs in, or tape over all of the opened refrig-
erant line fittings.
(4) Disconnect the front liquid line refrigerant line
coupler at the condenser outlet. See Refrigerant Line
Coupler 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) Remove the front liquid line from the engine
compartment.
INSTALLATION
(1) Remove the tape or plugs from the refrigerant
line fittings on the front liquid line and the con-
denser outlet. Connect the front liquid line to the
condenser outlet. See Refrigerant Line Coupler in the
Removal and Installation section of this group for the
procedures.
(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) Connect the battery negative cable.
(4) Evacuate the refrigerant system. See Refriger-
ant System Evacuate in the Service Procedures sec-
tion of this group.
(5) Charge the refrigerant system. See Refrigerant
System Charge in the Service Procedures section of
this group.
REAR
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 nut that secures the ground strap
to the inboard side of the rear liquid line block fit-
ting.
(5) Remove the screw that secures the rear liquid
line block fitting to the outlet of the filter-drier, and
disengage the fitting from the filter-drier. Install
plugs in, or tape over all of the opened refrigerant
line fittings.
(6) Disconnect the suction line from the suction
jumper. See refrigerant line coupler in the removal
and installation section.
(7) If the vehicle is equipped with the optional rear
overhead A/C unit, disconnect the refrigerant line
couplers near the dash panel between the suction
line jumper and the rear liquid line extension and
both of the underbody refrigerant lines. See Refriger-
Fig. 73 High Pressure Cut-Off Switch Remove/Install
1 – MANIFOLD
2 – LOW PRESSURE SERVICE PORT
3 – HIGH PRESSURE CUT-OFF SWITCH
4 – DISCHARGE LINE
5 – SUCTION LINE
24 - 60
HEATING AND AIR CONDITIONING
DN
REMOVAL AND INSTALLATION (Continued)
ant Line Coupler in the Removal and Installation
section of this group for the procedures. Install plugs
in, or tape over all of the opened refrigerant line fit-
tings.
(8) Disengage the clip that secures the rear liquid
line to the inner fender shield.
(9) Remove the nut that secures the rear liquid
line block fitting to the stud on the expansion valve,
and disengage the fitting from the expansion valve.
Install plugs in, or tape over all of the opened refrig-
erant line fittings.
(10) Remove the rear liquid line from the engine
compartment.
(11) Remove the suction line jumper from the rear
liquid line block fitting. See Suction Line Jumper in
the Removal and Installation section of this group for
the procedures.
INSTALLATION
(1) Install the suction line jumper into the rear liq-
uid line block fitting. See Suction Line Jumper in the
Removal and Installation section of this group for the
procedures.
(2) Remove the tape or plugs from the rear liquid
line block fitting and the expansion valve. Install the
rear liquid line block fitting over the expansion valve
stud and secure the connection with a nut. Tighten
the mounting nut to 22.5 N·m (200 in. lbs.).
(3) Install the rear liquid line in the clip on the
inner fender shield.
(4) If the vehicle is equipped with the optional rear
overhead A/C unit, remove the tape or plugs from the
refrigerant line fittings on the suction line jumper
and the rear liquid line extension and both of the
underbody refrigerant lines. Connect the underbody
refrigerant lines to the suction line jumper and the
rear liquid line extension. See Refrigerant Line Cou-
pler in the Removal and Installation section of this
group for the procedures.
(5) 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
Fig. 74 Liquid Line Remove/Install
1 – FRONT LIQUID LINE
2 – SCREW
3 – HIGH PRESSURE SERVICE PORT
4 – NUT
5 – SUCTION LINE JUMPER
6 – PLASTIC RETAINER
7 – REAR LIQUID LINE
8 – GROUND STRAP
9 – LIQUID LINE EXTENSION
10 – NUT
11 – EXPANSION VALVE
12 – CLIP
13 – CONDENSER OUTLET
14 – FILTER-DRIER
15 – CLIP
DN
HEATING AND AIR CONDITIONING
24 - 61
REMOVAL AND INSTALLATION (Continued)
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