Dodge Durango (DN). Manual — part 193

CAUTION:

•

Liquid refrigerant is corrosive to metal sur-

faces. Follow the operating instructions supplied
with the service equipment being used.

•

Never

add

R-12

to

a

refrigerant

system

designed to use R-134a. Damage to the system will
result.

•

R-12 refrigerant oil must not be mixed with

R-134a refrigerant oil. They are not compatible.

•

Do not use R-12 equipment or parts on the

R-134a system. Damage to the system will result.

•

Do not overcharge the refrigerant system. This

will cause excessive compressor head pressure
and can cause noise and system failure.

•

Recover the refrigerant before opening any fit-

ting or connection. Open the fittings with caution,
even after the system has been discharged. Never
open or loosen a connection before recovering the
refrigerant.

•

Do not remove the secondary retention clip

from any spring-lock coupler connection while the
refrigerant system is under pressure. Recover the
refrigerant before removing the secondary retention
clip. Open the fittings with caution, even after the
system has been discharged. Never open or loosen
a connection before recovering the refrigerant.

•

The refrigerant system must always be evacu-

ated before charging.

•

Do not open the refrigerant system or uncap a

replacement component until you are ready to ser-
vice the system. This will prevent contamination in
the system.

•

Before disconnecting a component, clean the

outside of the fittings thoroughly to prevent con-
tamination from entering the refrigerant system.

•

Immediately after disconnecting a component

from the refrigerant system, seal the open fittings
with a cap or plug.

•

Before connecting an open refrigerant fitting,

always install a new seal or gasket. Coat the fitting
and seal with clean refrigerant oil before connect-
ing.

•

Do not remove the sealing caps from a replace-

ment component until it is to be installed.

•

When installing a refrigerant line, avoid sharp

bends that may restrict refrigerant flow. Position the
refrigerant lines away from exhaust system compo-
nents or any sharp edges, which may damage the
line.

•

Tighten refrigerant fittings only to the specified

torque. The aluminum fittings used in the refriger-
ant system will not tolerate overtightening.

•

Refrigerant oil will absorb moisture from the

atmosphere if left uncapped. Do not open a con-
tainer of refrigerant oil until you are ready to use it.
Replace the cap on the oil container immediately

after using. Store refrigerant oil only in a clean, air-
tight, and moisture-free container.

•

Keep service tools and the work area clean.

Contamination of the refrigerant system through
careless work habits must be avoided.

COOLING SYSTEM REQUIREMENTS

To maintain the performance level of the heating-

air conditioning system, the engine cooling system
must be properly maintained. The use of a bug
screen is not recommended. Any obstructions in front
of the radiator or condenser will reduce the perfor-
mance of the air conditioning and engine cooling sys-
tems.

The engine cooling system includes the heater core

and the heater hoses. Refer to Group 7 - Cooling Sys-
tem for more information before the opening of, or
attempting any service to the engine cooling system.

REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS

Kinks or sharp bends in the refrigerant plumbing

will reduce the capacity of the entire system. High
pressures are produced in the system when it is oper-
ating. Extreme care must be exercised to make sure
that all refrigerant system connections are pressure
tight.

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. Sharp bends will reduce the
flow of refrigerant. The flexible hose lines should be
routed so they are at least 80 millimeters (3 inches)
from the exhaust manifold. It is a good practice to
inspect all flexible refrigerant system hose lines at
least once a year to make sure they are in good con-
dition and properly routed.

There are two types of refrigerant fittings:
• All fittings with O-rings need to be coated with

refrigerant oil before installation. Use only O-rings
that are the correct size and approved for use with
R-134a refrigerant. Failure to do so may result in a
leak.

• Unified plumbing connections with gaskets can-

not be serviced with O-rings. The gaskets are not
reusable and new gaskets do not require lubrication
before installing.

Using the proper tools when making a refrigerant

plumbing connection is very important. Improper
tools or improper use of the tools can damage the
refrigerant fittings.

The refrigerant must be recovered completely from

the system before opening any fitting or connection.
Open the fittings with caution, even after the refrig-
erant has been recovered. If any pressure is noticed

24 - 30

HEATING AND AIR CONDITIONING

DN

REMOVAL AND INSTALLATION (Continued)

as a fitting is loosened, tighten the fitting and
recover the refrigerant from the system again.

Do not discharge refrigerant into the atmosphere.

Use an R-134a refrigerant recovery/recycling device
that meets SAE Standard J2210.

The refrigerant system will remain chemically sta-

ble as long as pure, moisture-free R-134a refrigerant
and refrigerant oil is used. Dirt, moisture, or air can
upset this chemical stability. Operational troubles or
serious damage can occur if foreign material is
present in the refrigerant system.

When it is necessary to open the refrigerant sys-

tem, have everything needed to service the system
ready. The refrigerant system should not be left open
to the atmosphere any longer than necessary. Cap or
plug all lines and fittings as soon as they are opened
to prevent the entrance of dirt and moisture. All lines
and components in parts stock should be capped or
sealed until they are to be installed.

All tools, including the refrigerant recycling equip-

ment, the manifold gauge set, and test hoses should
be kept clean and dry. All tools and equipment must
be designed for R-134a refrigerant.

B-PILLAR REFRIGERANT LINE

The B-pillar refrigerant lines are used only on

models with the optional rear overhead A/C unit.
Both the B-pillar suction line and the B-pillar liquid
line are available for separate service replacement.
Each line may be removed independently from the
vehicle 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) Raise and support the vehicle.
(4) 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.

(5) Lower the vehicle.
(6) Remove the headliner from the passenger com-

partment of the vehicle. Refer to Group 23 - Body for
the procedures. The B-pillar upper and lower trim
must be removed.

(7) From the passenger compartment, remove the

fasteners that secure the block fittings at the top of
the B-pillar refrigerant lines to the rear overhead
A/C unit (nut from stud - liquid line) (nut and bolt -
suction line), and disengage the fittings (Fig. 13).
Install plugs in, or tape over all of the opened refrig-
erant line fittings.

(8) Remove the two screws that secure the B-pillar

refrigerant line clamps to the B-pillar (Fig. 14).

(9) Remove the two screws that secure the B-pillar

refrigerant line clamp and seal unit to the floor panel
at the base of the B-pillar.

(10) Tilt the top of the B-pillar refrigerant line

unit towards the front of the vehicle far enough so
that the lower end of the unit can be lifted out
through the hole in the floor panel.

Fig. 13 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

DN

HEATING AND AIR CONDITIONING

24 - 31

REMOVAL AND INSTALLATION (Continued)

(11) Remove the B-pillar refrigerant line unit from

the passenger compartment.

NOTE: If either the liquid line or the suction line is
removed from the B-pillar refrigerant line clamp and
seal, the clamp and seal will be damaged. Replace
the clamp and seal with a new unit.

INSTALLATION

(1) Position the B-pillar refrigerant line unit in the

passenger compartment with the lower end of the
lines inserted through the hole in the floor panel at
the base of the B-pillar, and the top end of the lines
oriented towards the front of the vehicle.

(2) Tilt the top of the B-pillar refrigerant line unit

up into position near the rear overhead A/C unit.

(3) 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 one
stud on the rear overhead A/C unit. Install the bolt
holding the suction line, and secure the connections
with the mounting nuts. Tighten the mounting nuts
to 11.3 N·m (100 in. lbs.).

(4) Position the B-pillar refrigerant line clamp and

seal over the hole in the floor panel and secure it
with two screws. Tighten the mounting screws to 2.2
N·m (20 in. lbs.).

(5) Position the B-pillar refrigerant line over the

mounting holes in the inner B-pillar and secure with
a screw. Tighten the mounting screw to 2.2 N·m (20
in. lbs.).

(6) Reinstall the headliner in the passenger com-

partment. Refer to Group 23 - Body for the proce-
dures. Reinstall the lower B-pillar trim panel, upper
trim panel, and seat belt bolt adjuster.

(7) Raise and support the vehicle.
(8) From under the vehicle, remove the tape or

plugs from the refrigerant line fittings at the under-
body and B-pillar liquid lines, and from the under-
body

and

B-pillar

suction

lines.

Connect

the

underbody refrigerant lines to the B-pillar refriger-
ant lines. See Refrigerant Line Coupler in the
Removal and Installation section of this group 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.

BLOWER MOTOR

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 and disassemble the heater-A/C hous-

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

(2) Remove the three screws that secure the

blower motor, air spoiler, and blower wheel assembly
to the heater-A/C housing (Fig. 15).

(3) Pull the blower motor and wheel assembly out

of the passenger compartment side of the heater-A/C
housing while feeding the blower motor wire harness,
grommet and connector through the hole on the dash
panel side of the housing.

Fig. 14 B-Pillar Refrigerant Lines Remove/Install

1 – OVERHEAD AIR CONDITIONING UNIT
2 – B-PILLAR
3 – B-PILLAR REFRIGERANT LINE
4 – SCREW
5 – CLAMP AND SEAL

24 - 32

HEATING AND AIR CONDITIONING

DN

REMOVAL AND INSTALLATION (Continued)

(4) Remove the blower wheel retainer clip and

remove the wheel from the blower motor shaft (Fig.
16).

INSTALLATION

(1) Press the blower wheel hub onto the blower

motor shaft. Be sure the flat on the blower motor
shaft is indexed to the flat on the inside of the blower
wheel hub.

(2) Install the retainer clip over the blower wheel

hub. The ears of the retainer clip must be indexed
over the flats on the blower motor shaft and blower
wheel hub.

(3) Place the blower motor, air spoiler, and wheel

assembly inside the heater-A/C housing and feed the
blower motor wire harness connector through the
grommet hole in the dash panel side of the housing.

(4) Pull the blower motor wiring through the hole

from the dash panel side of the heater-A/C housing
until the grommet is seated, while positioning the
blower motor and blower wheel assembly inside the
housing.

(5) Install the three screws that secure the blower

motor, air spoiler, and wheel assembly to the heater-
A/C housing. Tighten the screws to 2.2 N·m (20 in.
lbs.).

(6) Assemble and install the heater-A/C housing.

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

REAR

The rear blower motor is used only on models with

the optional rear overhead A/C unit. Because the rear
blower motor and wheel are factory balanced units,
the rear blower motor, wheel, housing and mounting
hardware are serviced only as a complete unit.

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the headliner from the passenger com-

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

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

wye fittings on each side of the rear overhead A/C
unit (Fig. 17).

Fig. 15 Blower Motor Remove/Install

1 – BLOWER WHEEL
2 – SCREWS
3 – AIR SPOILER
4 – BLOWER MOTOR HOUSING

Fig. 16 Blower Motor Wheel Remove/Install

1 – BLOWER MOTOR WHEEL
2 – RETAINER CLIP

Fig. 17 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 - 33

REMOVAL AND INSTALLATION (Continued)