Dodge Durango

 Service Manual

Heating and Air Conditioning » Removal and installation
Rear overhead a/c unit

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE GENERAL INFORMATION SECTION NEAR THE FRONT OF THIS GROUP BEFORE PERFORMING 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 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 nut from the bolt, (suction line) and nut from stud, (liquid line) that secure the block fittings at the top of the B-pillar refrigerant lines on the rear overhead A/C unit, and disengage the fittings (Fig. 80). 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. 81).

(6) Unplug the rear overhead A/C unit wire harness connector located at the left side of the unit.

(7) Loosen but do not remove the two screws that secure the mounting bracket on the left end of the rear overhead A/C unit to the left roof rail (Fig. 82).

(8) Support the right end of the rear overhead A/C unit while removing the two screws that secure the mounting bracket on the right end of the unit to the right roof rail.

(9) Slide the rear overhead A/C unit towards the right side of the vehicle far enough to disengage the slotted holes on the left end of the mounting bracket from the loosened screws in the left roof rail.

(10) Remove the rear overhead A/C unit from the passenger compartment.

Fig. 80 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. 81 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. 82 Rear Overhead A/C Unit Remove/Install

1 - ROOF PANEL

2 - SCREWS

3 - REAR OVERHEAD A/C UNIT

4 - SCREWS

INSTALLATION

(1) Engage the slotted holes in the left end of rear overhead A/C unit mounting bracket with the loosened screws in the left roof rail.

(2) Support the right end of the rear overhead A/C unit while installing the two screws that secure the mounting bracket on the right end of the unit to the right roof rail. Tighten all of the mounting screws to 11.9 N*m (105 in. lbs.).

(3) Plug in the rear overhead A/C unit wire harness connector located at the left side of the unit.

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

(5) 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.).

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

(7) Connect the battery negative cable.

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

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

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.

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