Dodge Durango (DN). Manual — part 202
NOTE: If the rear overhead A/C 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.
REFRIGERANT LINE COUPLER
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) Recover the refrigerant from the refrigerant
system. See Refrigerant Recovery in the Service Pro-
cedures section of this group.
(2) Remove the secondary clip from the spring-lock
coupler.
(3) Fit the proper size A/C line disconnect tool
(Special Tool Kit 7193) over the spring-lock coupler
cage (Fig. 83).
(4) Close the two halves of the A/C line disconnect
tool around the spring-lock coupler.
(5) Push the A/C line disconnect tool into the open
side of the coupler cage to expand the garter spring.
Once the garter spring is expanded and while still
pushing the disconnect tool into the open side of the
coupler cage, pull on the refrigerant line attached to
the female half of the coupler fitting until the flange
on the female fitting is separated from the garter
spring and cage on the male fitting within the dis-
connect tool.
NOTE: The garter spring may not release if the A/C
line disconnect tool is cocked while pushing it into
the coupler cage opening.
(6) Open and remove the A/C line disconnect tool
from the disconnected spring-lock coupler.
(7) Complete the separation of the two halves of
the coupler fitting.
INSTALLATION
(1) Check to ensure that the garter spring is
located within the cage of the male coupler fitting,
and that the garter spring is not damaged.
(a) If the garter spring is missing, install a new
spring by pushing it into the coupler cage opening.
(b) If the garter spring is damaged, remove it
from the coupler cage with a small wire hook (DO
NOT use a screwdriver) and install a new garter
spring.
(2) Clean any dirt or foreign material from both
halves of the coupler fitting.
(3) Install new O-rings on the male half of the cou-
pler fitting.
CAUTION: Use only the specified O-rings as they
are made of a special material for the R-134a sys-
tem. The use of any other O-rings may allow the
connection to leak intermittently during vehicle
operation.
(4) Lubricate the male fitting and O-rings, and the
inside of the female fitting with clean R-134a refrig-
erant oil. Use only refrigerant oil of the type recom-
mended for the compressor in the vehicle.
(5) Fit the female half of the coupler fitting over
the male half of the fitting.
(6) Push together firmly on the two halves of the
coupler fitting until the garter spring in the cage on
the male half of the fitting snaps over the flanged
end on the female half of the fitting.
(7) Ensure that the spring-lock coupler is fully
engaged by trying to separate the two coupler halves.
This is done by pulling the refrigerant lines on either
side of the coupler away from each other.
(8) Reinstall the secondary clip over the spring-
lock coupler cage.
SUCTION AND DISCHARGE 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. A good rule for the
flexible hose refrigerant lines is to keep the radius of
all bends at least ten times the diameter of the hose.
In addition, the flexible hose refrigerant lines should
be routed so they are at least 80 millimeters (3
inches) from the exhaust manifold.
Fig. 83 Refrigerant Line Spring-Lock Coupler
Disconnect
24 - 66
HEATING AND AIR CONDITIONING
DN
REMOVAL AND INSTALLATION (Continued)
High pressures are produced in the refrigerant sys-
tem when the air conditioning compressor is operat-
ing. Extreme care must be exercised to make sure
that each of the refrigerant system connections is
pressure-tight and leak free. It is a good practice to
inspect all flexible hose refrigerant lines at least once
a year to make sure they are in good condition and
properly routed.
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) Unplug the wire harness connector from the
high pressure cut-off switch.
(4) Disconnect the refrigerant line couplers at the
condenser and the suction line jumper. 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 nut that secures the refrigerant
line support bracket near the compressor.
(6) Remove the screw that secures the refrigerant
line manifold to the compressor (Fig. 84). Install
plugs in, or tape over all of the opened refrigerant
line fittings.
(7) Remove the suction and discharge line assem-
bly from the vehicle.
INSTALLATION
(1) Remove the tape or plugs from all of the refrig-
erant line fittings. Install the refrigerant line cou-
plers to the condenser and the suction line jumper.
See Refrigerant Line Coupler in the Removal and
Installation section of this group for the procedures.
(2) Install the refrigerant line manifold to the com-
pressor. Tighten the mounting screw to 22 N·m (200
in. lbs.).
(3) Install the nut that secures the refrigerant line
support bracket near the compressor.
(4) Plug in the wire harness connector to the high
pressure cut-off switch.
(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.
SUCTION LINE JUMPER
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.
REMOVAL
(1) Disconnect and isolate the battery negative
cable.
(2) Remove the low pressure cut-off switch from
the fitting on the suction line jumper. See Low Pres-
sure Cut-Off Switch in the Removal and Installation
section of this group for the procedures.
(3) Recover the refrigerant from the refrigerant
system. See Refrigerant Recovery in the Service Pro-
cedures section of this group.
(4) Disconnect the refrigerant line coupler between
the suction line and the suction line jumper. See
Refrigerant Line Coupler in the Removal and Instal-
lation section of this group for the procedures. Install
plugs in, or tape over all of the opened refrigerant
line fittings.
Fig. 84 Suction and Discharge Line Remove/Install
1 – SUCTION AND DISCHARGE LINE ASSEMBLY
2 – EXPANSION VALVE
3 – LINE CLIP
4 – LOW PRESSURE SERVICE PORT
5 – HIGH PRESSURE CUT-OFF SWITCH
6 – CONDENSER
DN
HEATING AND AIR CONDITIONING
24 - 67
REMOVAL AND INSTALLATION (Continued)
(5) Remove the rear liquid line from the engine
compartment. See Liquid Line in the Removal and
Installation section of this group for the procedures.
(6) Slide the plastic retainer that secures the suc-
tion line jumper out of the saddle formation at the
top of the rear liquid line block fitting. Secure block,
preferably in a vise. Tap the plastic retainer out with
a hammer and flat-bladed screwdriver.
(7) Remove the suction line jumper from the rear
liquid line block fitting.
INSTALLATION
(1) Using a new O-ring, install the suction line
jumper into the saddle formation at the top of the
rear liquid line block fitting.
(2) Slide the plastic retainer that secures the suc-
tion line jumper into the rear liquid line block fitting.
(3) Install the rear liquid line into the engine com-
partment. See Liquid Line in the Removal and
Installation section of this group for the procedures.
(4) Remove the tape or plugs from the refrigerant
line fittings on the suction line and the suction line
jumper. Install the suction line to the suction line
jumper. See Refrigerant Line Coupler in the Removal
and Installation section of this group for the proce-
dures.
(5) Install the low pressure cut-off switch to the
fitting on the suction line jumper. See Low Pressure
Cut-Off Switch in the Removal and Installation sec-
tion of this group for the procedures.
(6) Connect the battery negative cable.
(7) Evacuate the refrigerant system. See Refriger-
ant System Evacuate in the Service Procedures sec-
tion of this group.
(8) Charge the refrigerant system. See Refrigerant
System Charge in the Service Procedures section of
this group.
TEMPERATURE CONTROL CABLE
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) Roll down the instrument panel assembly, 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.
(3) Disconnect the temperature control cable from
the heater-A/C control. See Heater-A/C Control in the
Removal and Installation section of this group for the
procedures.
(4) Disconnect the temperature control cable hous-
ing flag retainer from the receptacle on the top of the
heater-A/C housing (Fig. 85).
(5) Pull the temperature control cable core self-ad-
juster clip off of the pin on the end of the blend-air
door lever.
(6) Remove the temperature control cable from the
vehicle.
INSTALLATION
Before installing the temperature control cable, be
certain that the self-adjuster clip is properly posi-
tioned (Fig. 86). This measurement must be made
with the cable end bottomed against the flag retainer
on the heater-A/C control end of the cable housing.
The measurement is taken from the end of the flag
retainer on the heater-A/C housing end of the cable
to the center of the self-adjuster clip. If the self-ad-
juster clip is not properly positioned, slide the clip up
or down the cable core as required to achieve the
specified dimension.
(1) Connect the temperature control cable to the
heater-A/C control. See Heater-A/C Control in the
Fig. 85 Temperature Control Cable Remove/Install
1 – FLAG RETAINER
2 – ADJUSTER CLIP
3 – BLEND-AIR DOOR LEVER
4 – HEATER-A/C HOUSING
5 – TEMPERATURE CONTROL CABLE
24 - 68
HEATING AND AIR CONDITIONING
DN
REMOVAL AND INSTALLATION (Continued)
Removal and Installation section of this group for the
procedures.
(2) Route the cable through the instrument panel.
Position the cable end near the connection points on
the HVAC unit assembly, making sure not to kink or
distort the cable.
(3) Push the temperature control cable core self-
adjuster clip onto the pin on the end of the blend-air
door lever.
(4) Snap the temperature control cable housing
flag retainer into the receiver on the top of the heat-
er-A/C housing.
(5) Reinstall the instrument panel assembly. Refer
to Instrument Panel Assembly in the Removal and
Installation section of Group 8E - Instrument Panel
Systems for the procedures.
(6) Connect the battery negative cable.
(7) Adjust the temperature control cable. See Tem-
perature Control Cable in the Adjustments section of
this group for the procedures.
UNDERBODY REFRIGERANT LINE
The underbody refrigerant lines are used only on
models with the optional rear overhead A/C unit.
Both the underbody suction line and the underbody
liquid line are available for separate service replace-
ment, and may be removed from the vehicle indepen-
dently for service.
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.
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) From the engine compartment, disconnect the
underbody liquid line refrigerant line coupler at the
liquid line extension and the underbody suction line
refrigerant line coupler at the suction line jumper
(Fig. 87). 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.
(4) Raise and support the vehicle.
(5) From under the vehicle, disconnect the under-
body liquid line refrigerant line coupler at the B-pil-
lar liquid line and the underbody suction line
refrigerant line coupler at the B-pillar suction line.
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 refrig-
erant line fittings.
(6) Remove the screws that secure the three
underbody refrigerant line clamps to the underbody.
(7) Remove the underbody refrigerant line unit
from the vehicle.
INSTALLATION
(1) From under the vehicle, position the underbody
refrigerant line unit to the underbody and secure the
refrigerant line clamps with the mounting screws in
Fig. 86 Temperature Control Cable Self-Adjuster Clip
1 – SELF-ADJUSTER CLIP
2 – HEATER-A/C CONTROL CABLE HOUSING FLAG RETAINER-
HOUSING END
3 – HEATER-A/C CONTROL CABLE HOUSING FLAG RETAINER-
CONTROL END
4 – CABLE END
DN
HEATING AND AIR CONDITIONING
24 - 69
REMOVAL AND INSTALLATION (Continued)
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