Dodge Dakota (R1). Manual - part 795

VIBRATION

Possible causes of blower motor vibration include:
• Improper blower motor mounting

• Improper blower wheel mounting

• Blower wheel out of balance or deformed

• Blower motor faulty.

NOISE

To verify that the blower is the source of the noise,

unplug the blower motor wire harness connector and
operate the heater-A/C system. If the noise goes
away, possible causes include:

• Foreign material in the heater-A/C housing

• Improper blower motor mounting

• Improper blower wheel mounting

• Blower motor faulty.

REMOVAL

FURTHER

DIAGNOSIS

SERVICE.

FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.

(1) Remove and disassemble the heater-A/C hous-

ing (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/HVAC HOUSING - REMOVAL)
and (Refer to 24 - HEATING & AIR CONDITION-
ING/DISTRIBUTION/HVAC

HOUSING

DISAS-

SEMBLY).

(2) Remove the three screws that secure the

blower motor and blower wheel assembly to the heat-
er-A/C housing.

(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.

(4) Remove the blower wheel retainer clip and

remove the wheel from the blower motor shaft.

INSTALLATION

(1) 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.

(2) 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.

(3) 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.).

(4) Plug blower motor connections together.
(5) Carefully install passenger side carpet.
(6) Install lower right kick panel (Refer to 23 -

BODY/INTERIOR/COWL TRIM COVER - INSTAL-
LATION)

DEFROSTER DUCTS

REMOVAL

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT
DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING FURTHER DIAGNOSIS OR SERVICE. THIS
IS THE ONLY SURE WAY TO DISABLE THE AIRBAG
SYSTEM. FAILURE TO TAKE THE PROPER PRE-
CAUTIONS COULD RESULT IN ACCIDENTAL AIR-
BAG DEPLOYMENT AND POSSIBLE PERSONAL
INJURY.

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the instrument panel from the vehicle.

(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).

(3) Place the instrument panel face down on a

suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.

(4) Remove the fasteners that secure the defroster

duct to the instrument panel armature.

(5) Remove the defroster duct from the instrument

panel.

24 - 26

DISTRIBUTION

BLOWER MOTOR (Continued)

INSTALLATION

(1) Position the defroster duct to the instrument

panel.

(2) Install the fasteners that secure the defroster

duct to the instrument panel armature.

(3) Reinstall the instrument panel in the vehicle.

(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT

PANEL

ASSEMBLY

INSTALLA-

TION).

(4) Reconnect the battery negative cable.

FLOOR DISTRIBUTION DUCTS

REMOVAL

(1) Roll back the carpet on the front floor from

under the instrument panel toward the rear of the
vehicle. (Refer to 23 - BODY/INTERIOR/CARPETS
AND FLOOR MATS - REMOVAL).

(2) Lift the center floor distribution duct upward

far enough to disengage its locator hole from the
weld stud on the front floor panel.

(3) Pull the floor distribution duct assembly rear-

ward far enough to disengage the center floor distri-
bution duct from the outlet on the bottom of the
heater-A/C housing unit.

INSTALLATION

(1) Assemble the right and/or left floor distribution

ducts onto the center floor distribution duct as
required.

(2) Slide

the

floor

distribution

duct

assembly

under the instrument panel center stack far enough
to engage the center floor distribution duct with the
outlet on the bottom of the heater-A/C housing unit.

(3) Align the locator hole on the center floor distri-

bution duct with the weld stud on the front floor
panel.

(4) Using hand pressure, push the locator hole of

the center floor distribution duct down over the weld
stud on the front floor panel.

(5) Reinstall the carpet onto the front floor panel

and under the instrument panel. (Refer to 23 -
BODY/INTERIOR/CARPETS AND FLOOR MATS -
INSTALLATION).

HVAC HOUSING

DESCRIPTION

All vehicles are equipped with a common heater-

A/C housing assembly. The system combines air con-
ditioning, heating, and ventilating capabilities in a
single unit housing mounted under the instrument
panel. On heater-only systems, the evaporator coil
and recirculation air door are omitted from the hous-
ing.

OPERATION

Outside fresh air enters the vehicle through the

cowl top opening at the base of the windshield, and
passes through a plenum chamber to the heater-A/C
system blower housing. Air flow velocity can then be
adjusted with the blower motor speed selector switch
on the heater-A/C control panel. The air intake open-
ings must be kept free of snow, ice, leaves, and other
obstructions for the heater-A/C system to receive a
sufficient volume of outside air.

It is also important to keep the air intake openings

clear of debris because leaf particles and other debris
that are small enough to pass through the cowl ple-
num screen can accumulate within the heater-A/C
housing. The closed, warm, damp and dark environ-
ment created within the heater-A/C housing is ideal
for the growth of certain molds, mildews and other
fungi. Any accumulation of decaying plant matter
provides an additional food source for fungal spores,
which enter the housing with the fresh air. Excess
debris, as well as objectionable odors created by
decaying plant matter and growing fungi can be dis-
charged into the passenger compartment during
heater-A/C system operation.

The heater and optional air conditioner are blend-

air type systems. In a blend-air system, a blend-air
door controls the amount of unconditioned air (or
cooled air from the evaporator on models with air
conditioning) that is allowed to flow through, or
around, the heater core. A temperature control knob
on the heater-A/C control panel determines the dis-
charge air temperature. By moving a electric actua-
tor which operates the blend-air door. This allows an
almost immediate manual control of the output air
temperature of the system.

DISTRIBUTION

24 - 27

DEFROSTER DUCTS (Continued)

The mode control knob on the heater-only or heat-

er-A/C control panel is used to direct the conditioned
air to the selected system outlets. The mode control
switches use an electric actuator to control the mode
doors.

The optional air conditioner for all models is

designed for the use of non-CFC, R-134a refrigerant.
The air conditioning system has an evaporator to cool
and dehumidify the incoming air prior to blending it
with the heated air. This air conditioning system
uses a fixed orifice tube in the liquid line between
the condenser and the evaporator coil to meter refrig-
erant flow to the evaporator coil.

REMOVAL- HVAC HOUSING PLENUM ADAPTER

FURTHER

DIAGNOSIS

SERVICE.

FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.

(1) Remove the heater-A/C housing from the vehi-

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

(2) Slide the heater-A/C housing plenum adapter

all the way to one side of the plenum opening.

(3) Pull downwards sharply and firmly on the

opposite side of the plenum adapter to disengage the
snap feature from the plenum opening.

(4) Remove the plenum adapter from the plenum

panel.

(5) When reinstalling the heater-A/C housing ple-

num adapter to the plenum panel opening, be certain
that the snap features on each side of the adapter
are fully engaged with the sides of the plenum panel
opening. This must be a water tight connection to
prevent leaks.

REMOVAL- HVAC HOUSING

The heater-A/C housing assembly must be removed

from the vehicle and disassembled for service access
of the blower motor, blower motor wheel, heater core,
evaporator coil, blend-air door, and each of the vari-
ous mode control doors.

WARNING: ON VEHICLES EQUIPPED WITH AIR-
BAGS, DISABLE THE AIRBAG SYSTEM BEFORE
ATTEMPTING ANY STEERING WHEEL, STEERING
COLUMN, OR INSTRUMENT PANEL COMPONENT

DIAGNOSIS OR SERVICE. DISCONNECT AND ISO-
LATE THE BATTERY NEGATIVE (GROUND) CABLE,
THEN WAIT TWO MINUTES FOR THE AIRBAG SYS-
TEM CAPACITOR TO DISCHARGE BEFORE PER-
FORMING

FURTHER

DIAGNOSIS

SERVICE.

FAILURE TO TAKE THE PROPER PRECAUTIONS
COULD RESULT IN ACCIDENTAL AIRBAG DEPLOY-
MENT AND POSSIBLE PERSONAL INJURY.

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the instrument panel from the vehicle.

(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).

(3) If the vehicle is not equipped with air condi-

tioning, go to Step 6. If the vehicle is equipped with
air conditioning, recover the refrigerant from the
refrigerant system (Refer to 24 - HEATING & AIR
CONDITIONING/PLUMBING/REFRIGERANT

STANDARD PROCEDURE).

(4) Disconnect the liquid line refrigerant line fit-

ting from the evaporator inlet tube (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
REMOVAL). Install plugs in, or tape over all of the
opened refrigerant line fittings.

(5) Disconnect the accumulator inlet tube refriger-

ant line fitting from the evaporator outlet tube (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - REMOVAL). Install plugs in, or tape over all of
the opened refrigerant line fittings.

(6) Drain the engine cooling system (Refer to 7 -

COOLING - STANDARD PROCEDURE).

(7) Disconnect the heater hoses from the heater

core tubes. Refer to Group 7 - Cooling System for the
procedures. Install plugs in, or tape over the opened
heater core tubes.

(8) Remove the two screws that retain the hanger

strap and air inlet to the plenum.

(9) Remove the nut that secures the heater-A/C

housing mounting brace to the stud on the passenger
compartment side of the dash panel.

(10) Pull the heater-A/C housing rearward far

enough for the mounting studs and the evaporator
condensate drain tube to clear the dash panel holes.

(11) Remove the heater-A/C housing from the vehi-

cle.

INSTALLATION- HVAC HOUSING PLENUM
ADAPTER

(1) Install the heater-A/C housing plenum adapter

to the plenum panel opening, be certain that the
snap features on each side of the adapter are fully
engaged with the sides of the plenum panel opening.
This must be a water tight connection to prevent
leaks.

24 - 28

DISTRIBUTION

HVAC HOUSING (Continued)

(2) Install the plenum adapter to the plenum

panel.

(3) Push upwards sharply and firmly on the oppo-

site side of the plenum adapter to disengage the snap
feature to the plenum opening.

(4) Slide the heater-A/C housing plenum adapter

onto the plenum opening.

(5) Install the heater-A/C housing to the vehicle.

See Heater-A/C housing in the Removal and Installa-
tion section of this group for the procedures.

INSTALLATION- HVAC HOUSING

(1) Position the heater-A/C housing to the dash

panel. Be certain that the evaporator condensate
drain tube and the housing mounting studs are
inserted into their correct mounting holes.

(2) Install the screw that secures the air inlet to

the plenum.

(3) Install and tighten the four nuts onto the heat-

er-A/C housing mounting studs on the engine com-
partment side of the dash panel. Tighten the nuts to
7 N·m (60 in. lbs.).

(4) Install the screw that secures the hanger strap

to the plenum.

(5) Unplug or remove the tape from the heater

core tubes. Connect the heater hoses to the heater
core tubes and fill the engine cooling system (Refer to
7 - COOLING - STANDARD PROCEDURE).

(6) If the vehicle is not equipped with air condi-

tioning, go to Step 10. If the vehicle is equipped with
air conditioning, unplug or remove the tape from the
accumulator inlet tube and the evaporator outlet
tube fittings. Connect the accumulator inlet tube cou-
pler to the evaporator outlet tube (Refer to 24 -
HEATING & AIR CONDITIONING/PLUMBING -
INSTALLATION).

(7) Unplug or remove the tape from the liquid line

and the evaporator inlet tube fittings. Connect the
liquid line coupler to the evaporator inlet tube (Refer
to 24 - HEATING & AIR CONDITIONING/PLUMB-
ING - INSTALLATION).

(8) Evacuate the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).

(9) Charge the refrigerant system (Refer to 24 -

HEATING & AIR CONDITIONING/PLUMBING/RE-
FRIGERANT - STANDARD PROCEDURE).

(10) Reinstall the instrument panel in the vehicle

(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT

PANEL

ASSEMBLY

INSTALLA-

TION).

(11) Connect the battery negative cable.
(12) Start the engine and check for proper opera-

tion of the heating and air conditioning systems.

INSTRUMENT PANEL
DEMISTER DUCTS

REMOVAL

(1) Disconnect and isolate the battery negative

cable.

(2) Remove the instrument panel from the vehicle.

(Refer to 23 - BODY/INSTRUMENT PANEL/IN-
STRUMENT PANEL ASSEMBLY - REMOVAL).

(3) Place the instrument panel face down on a

suitable work surface. Be certain to take the proper
precautions to protect the face of the instrument
panel from cosmetic damage.

(4) Remove the fasteners that secure the demister

ducts to the instrument panel armature.

(5) Disengage the demister ducts from the demis-

ter outlets.

(6) Remove the demister ducts from the instru-

ment panel.

INSTALLATION

(1) Position the demister ducts to the instrument

panel.

DISTRIBUTION

24 - 29

HVAC HOUSING (Continued)

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