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

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

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

GROUP

PASSIVE

RESTRAINT SYSTEMS BEFORE ATTEMPTING ANY
STEERING

WHEEL,

STEERING

COLUMN,

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

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-

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

HEATING AND AIR CONDITIONING

24 - 69

REMOVAL AND INSTALLATION (Continued)

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