Dodge Durango (DN). Manual — part 192

(3) Determine the vacuum line color of the vacuum

circuit that is leaking. To determine the vacuum line
colors, see the Vacuum Circuits chart (Fig. 12).

(4) Disconnect and plug the vacuum line from the

component (fitting, actuator, valve, switch, or reser-
voir) on the other end of the leaking circuit. Instru-
ment panel disassembly or removal may be necessary
to gain access to some components. See the Removal
and Installation section of this group for more infor-
mation.

(5) Connect the test set hose or probe to the open

end of the leaking circuit. The test set gauge should
return to the 27 kPa (8 in. Hg.) setting shortly after

each connection is made. If OK, replace the faulty
disconnected component. If not OK, go to Step 6.

(6) To locate a leak in a vacuum line, leave one

end of the line plugged and connect the test set hose
or probe to the other end of the line. Run your fin-
gers slowly along the line while watching the test set
gauge. The vacuum reading will fluctuate when your
fingers contact the source of the leak. To repair the
vacuum line, cut out the leaking section of the line.
Then, insert the loose ends of the line into a suitable
length of 3 millimeter (0.125 inch) inside diameter
rubber hose.

24 - 26

HEATING AND AIR CONDITIONING

DN

DIAGNOSIS AND TESTING (Continued)

VACUUM CIRCUIT LEGEND

I.D.

FUNCTION

COLOR

A

Recirculation Actuator

(Door Closed)

Light Green

B

Floor-Defrost Actuator

(Mid Position

Yellow

C

Panel-Defrost Actuator

(Full Position)

Brown

D

Floor-Defrost Actuator

(Full Position)

Blue

E

Vacuum Supply

(Reservoir)

Black

F

Panel-Defrost Actuator

(Mid Position)

Red

G

Recirculation Actuator

(Door Open)

Dark Green

Fig. 12 Vacuum Circuits

DN

HEATING AND AIR CONDITIONING

24 - 27

DIAGNOSIS AND TESTING (Continued)

SERVICE PROCEDURES

REFRIGERANT OIL LEVEL

When an air conditioning system is assembled at

the factory, all components except the compressor are
refrigerant oil free. After the refrigerant system has
been charged and operated, the refrigerant oil in the
compressor is dispersed throughout the refrigerant
system. The evaporator, filter-drier, condenser, and
compressor will each retain a significant amount of
the needed refrigerant oil.

It is important to have the correct amount of oil in

the refrigerant system. This ensures proper lubrica-
tion of the compressor. Too little oil will result in
damage to the compressor. Too much oil will reduce
the cooling capacity of the air conditioning system.

It will not be necessary to check the oil level in the

compressor or to add oil, unless there has been an oil
loss. An oil loss may occur due to a rupture or leak
from a refrigerant line, a connector fitting, a compo-
nent, or a component seal. If a leak occurs, add 30
milliliters (1 fluid ounce) of refrigerant oil to the
refrigerant system after the repair has been made.
Refrigerant oil loss will be evident at the leak point
by the presence of a wet, shiny surface around the
leak.

Refrigerant oil must be added when a filter-drier,

evaporator coil, or condenser are replaced. See the
Refrigerant Oil Capacities chart. When a compressor
is replaced, the refrigerant oil must be drained from
the old compressor and measured. Drain all of the
refrigerant oil from the new compressor, then fill the
new compressor with the same amount of refrigerant
oil that was drained out of the old compressor.

REFRIGERANT RECOVERY

WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE
RECOVERING REFRIGERANT.

A R-134a refrigerant recovery/recycling/charging

station that meets SAE Standard J2210 must be
used to recover the refrigerant from an R-134a refrig-
erant system. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.

REFRIGERANT SYSTEM CHARGE

WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE
CHARGING THE REFRIGERANT SYSTEM.

After the refrigerant system has been tested for

leaks and evacuated, a refrigerant charge can be
injected into the system. See Refrigerant Charge
Capacity in the Service Procedures section of this
group for the proper amount of the refrigerant
charge.

A R-134a refrigerant recovery/recycling/charging

station that meets SAE Standard J2210 must be
used to charge the refrigerant system with R-134a
refrigerant. Refer to the operating instructions sup-
plied by the equipment manufacturer for the proper
care and use of this equipment.

REFRIGERANT CHARGE CAPACITY

The R-134a refrigerant system charge capacity for

this vehicle is: Single Unit: 0.793 kilograms (28 ounc-
es), Dual Unit: 0.907 kilograms (32 ounces).

REFRIGERANT SYSTEM EVACUATE

WARNING: REVIEW THE WARNINGS AND CAU-
TIONS IN THE GENERAL INFORMATION SECTION
NEAR THE FRONT OF THIS GROUP BEFORE EVAC-
UATING THE SYSTEM.

If the refrigerant system has been open to the

atmosphere, it must be evacuated before the system
can be charged. If moisture and air enters the system
and becomes mixed with the refrigerant, the com-
pressor head pressure will rise above acceptable
operating levels. This will reduce the performance of
the air conditioner and damage the compressor.
Evacuating the refrigerant system will remove the
air and boil the moisture out of the system at near
room temperature. To evacuate the refrigerant sys-
tem, use the following procedure:

Refrigerant Oil Capacities

Component

ml

fl oz

A/C System 4.7 L

(Front Only)

165

5.5

A/C System 4.7 L

(Front & Rear)

240

8

A/C System 5.9L (Front Only)

180

6.1

A/C System 5.9L

(Front & Rear)

240

8

Filter-Drier

30

1

Condenser

30

1

Evaporator (Front)

60

2

Evaporator (Rear)

30

1

Compressor

drain and measure
the oil from the old
compressor - see
text.

24 - 28

HEATING AND AIR CONDITIONING

DN

(1) Connect a R-134a refrigerant recovery/recy-

cling/charging station that meets SAE Standard
J2210 and a manifold gauge set to the refrigerant
system of the vehicle.

(2) Open the low and high side valves and start

the charging station vacuum pump. When the suc-
tion gauge reads 88 kPa (26 in. Hg.) vacuum or
greater, close all of the valves and turn off the vac-
uum pump.

(a) If the refrigerant system fails to reach the

specified vacuum, the system has a leak that must
be corrected. See Refrigerant System Leaks in the
Diagnosis and Testing section of this group for the
procedures.

(b) If the refrigerant system maintains the spec-

ified vacuum for five minutes, restart the vacuum
pump, open the suction and discharge valves and
evacuate the system for an additional ten minutes.
(3) Close all of the valves, and turn off the charg-

ing station vacuum pump.

(4) The refrigerant system is now ready to be

charged with R-134a refrigerant. See Refrigerant
System Charge in the Service Procedures section of
this group.

REMOVAL AND INSTALLATION

SERVICE WARNINGS AND PRECAUTIONS

WARNING:

•

THE AIR CONDITIONING SYSTEM CONTAINS

REFRIGERANT UNDER HIGH PRESSURE. SEVERE
PERSONAL INJURY MAY RESULT FROM IMPROPER
SERVICE PROCEDURES. REPAIRS SHOULD ONLY
BE PERFORMED BY QUALIFIED SERVICE PERSON-
NEL.

•

AVOID BREATHING THE REFRIGERANT AND

REFRIGERANT OIL VAPOR OR MIST. EXPOSURE
MAY IRRITATE THE EYES, NOSE, AND/OR THROAT.
WEAR EYE PROTECTION WHEN SERVICING THE
AIR CONDITIONING REFRIGERANT SYSTEM. SERI-
OUS EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CON-
TACT OCCURS, SEEK MEDICAL ATTENTION IMME-
DIATELY.

•

DO

NOT

EXPOSE

THE

REFRIGERANT

TO

OPEN

FLAME.

POISONOUS

GAS

IS

CREATED

WHEN

REFRIGERANT

IS

BURNED.

AN

ELEC-

TRONIC LEAK DETECTOR IS RECOMMENDED.

•

IF

ACCIDENTAL

SYSTEM

DISCHARGE

OCCURS, VENTILATE THE WORK AREA BEFORE
RESUMING

SERVICE.

LARGE

AMOUNTS

OF

REFRIGERANT RELEASED IN A CLOSED WORK
AREA WILL DISPLACE THE OXYGEN AND CAUSE
SUFFOCATION.

•

THE EVAPORATION RATE OF R-134a REFRIG-

ERANT AT AVERAGE TEMPERATURE AND ALTI-
TUDE

IS

EXTREMELY

HIGH.

AS

A

RESULT,

ANYTHING THAT COMES IN CONTACT WITH THE
REFRIGERANT WILL FREEZE. ALWAYS PROTECT
THE SKIN OR DELICATE OBJECTS FROM DIRECT
CONTACT WITH THE REFRIGERANT.

•

THE R-134a SERVICE EQUIPMENT OR THE

VEHICLE REFRIGERANT SYSTEM SHOULD NOT BE
PRESSURE TESTED OR LEAK TESTED WITH COM-
PRESSED AIR. SOME MIXTURES OF AIR AND
R-134a HAVE BEEN SHOWN TO BE COMBUSTIBLE
AT ELEVATED PRESSURES. THESE MIXTURES ARE
POTENTIALLY DANGEROUS, AND MAY RESULT IN
FIRE OR EXPLOSION CAUSING INJURY OR PROP-
ERTY DAMAGE.

DN

HEATING AND AIR CONDITIONING

24 - 29

SERVICE PROCEDURES (Continued)