Dodge Durango

 Service Manual

Heating and Air Conditioning » Removal and installation
Evaporator coil

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION SECTION NEAR THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION.

WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, 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 PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY.

FRONT

REMOVAL

(1) Remove the heater-A/C housing from the vehicle, and remove the housing cover. See Heater-A/C Housing in the Removal and Installation section of this group for the procedures.

(2) Lift the front evaporator coil out of the heater- A/C housing (Fig. 50).

Fig. 50 Evaporator Coil Remove/Install

1 - EVAPORATOR COIL

2 - HEATER-A/C HOUSING

INSTALLATION

(1) Insert the front evaporator coil into the bottom of the heater-A/C housing.

(2) Reassemble and reinstall the heater-A/C housing in the vehicle. See Heater-A/C Housing in the Removal and Installation section of this group for the procedures.

NOTE: If the front evaporator coil is replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the compressor in the vehicle.

REAR

The rear evaporator coil is used only on models with the optional rear overhead A/C unit.

REMOVAL

(1) Disconnect and isolate the battery negative cable.

(2) Recover the refrigerant from the refrigerant system. See Refrigerant Recovery in the Service Procedures section of this group.

(3) Remove the headliner from the passenger compartment of the vehicle. Refer to Group 23 - Body for the procedures.

(4) From the passenger compartment, remove the nuts that secure the block fittings at the top of the B-pillar refrigerant lines to the studs on the rear overhead A/C unit, and disengage the fittings (Fig.

51). Install plugs in, or tape over all of the opened refrigerant line fittings.

(5) Disconnect the B-pillar drain hoses from the wye fittings on each side of the rear overhead A/C unit (Fig. 52).

(6) Remove the nine screws that secure the lower housing cover to the rear overhead A/C unit.

(7) Release the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit (Fig. 53).

(8) Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover while removing the cover from the unit.

(9) Remove the screw that secures the rear overhead A/C refrigerant tube and block fitting retaining strap to the right side of the upper housing cover (Fig. 54).

(10) Remove the two screws that secure the rear evaporator coil to the rear overhead A/C unit upper housing cover (Fig. 55).

(11) Remove the rear evaporator coil from the rear overhead A/C unit.

Fig. 51 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

Fig. 52 Rear Overhead A/C Drain Hose Remove/ Install

1 - REAR OVERHEAD A/C UNIT

2 - WYE FITTING

3 - CLIP

4 - GROMMET

5 - DRAIN HOSE

Fig. 53 Rear Overhead A/C Unit Lower Housing Cover Remove/Install

1 - REAR OVERHEAD A/C UNIT LOWER HOUSING COVER

2 - SNAP RETAINER

3 - OUTLET SIDE

4 - BLOWER MOTOR SWITCH WIRE HARNESS CONNECTOR

5 - INLET SIDE

6 - DRAIN HOSES

Fig. 54 Rear A/C Tube Retaining Strap Remove/ Install

1 - BLOWER WHEEL

2 - RETAINING STRAP

3 - SCREW

4 - EVAPORATOR COIL

INSTALLATION

(1) Position the rear evaporator coil to the rear overhead A/C unit and secure with two mounting screws. Tighten the mounting screws to 2.2 N*m (20 in. lbs.).

(2) Install the rear overhead A/C refrigerant tube and block fitting retaining strap to the right side of the upper housing cover and secure with a screw.

Tighten the mounting screws to 2.2 N*m (20 in. lbs.).

Fig. 55 Rear Evaporator Coil Remove/Install

1 - BLOWER WHEEL AND HOUSING

2 - SCREWS

3 - EVAPORATOR COIL

(3) Feed the rear blower motor switch wire harness and connector through the hole in the right end of the rear overhead A/C unit lower housing cover while positioning the cover to the unit.

(4) Be certain that the lower housing cover snap retainer near the center of the outlet side (rear) of the rear overhead A/C unit is engaged.

(5) Install the nine screws that secure the lower housing cover to the rear overhead A/C unit. Tighten the mounting screws to 2.2 N*m (20 in. lbs.).

(6) Connect the B-pillar drain hoses to the wye fittings on each side of the rear overhead A/C unit.

(7) 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 two studs on the rear overhead A/C unit and secure the connections with the mounting nuts. Tighten the mounting nuts to 11.3 N*m (100 in. lbs.).

(8) Reinstall the headliner in the passenger compartment of the vehicle. Refer to Group 23 - Body for the procedures.

(9) Connect the battery negative cable.

(10) Evacuate the refrigerant system. See Refrigerant System Evacuate in the Service Procedures section of this group.

(11) Charge the refrigerant system. See Refrigerant System Charge in the Service Procedures section of this group.

NOTE: If the rear evaporator coil and expansion valve 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.

Service warnings and precautions

B-pillar refrigerant line

Blower motor

Blower motor relay

Blower motor resistor

Compressor

Compressor clutch

Compressor clutch relay

Condenser

Ducts and outlets

Electronic cycling clutch switch

Evaporator coil

Expansion valve

Filter-drier

Heater-a/c control

Heater-a/c housing

Heater-a/c housing door

Heater core

High pressure cut-off switch

Liquid line

Low pressure cut-off switch

Mode door vacuum actuator

Rear blower motor switch

Rear overhead a/c unit

Refrigerant line coupler

Suction and discharge line

Suction line jumper

Temperature control cable

Underbody refrigerant line

Vacuum check valve

Vacuum reservoir