
Dodge Durango
Service Manual
Heating and Air Conditioning » 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 PERSONNEL.
- 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. SERIOUS
EYE INJURY CAN RESULT FROM DIRECT
CONTACT WITH THE REFRIGERANT. IF EYE CONTACT
OCCURS, SEEK MEDICAL ATTENTION IMMEDIATELY.
- DO NOT EXPOSE THE REFRIGERANT TO
OPEN FLAME. POISONOUS GAS IS CREATED
WHEN REFRIGERANT IS BURNED. AN ELECTRONIC
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 REFRIGERANT
AT AVERAGE TEMPERATURE AND ALTITUDE
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 COMPRESSED
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 PROPERTY
DAMAGE.
CAUTION:
- Liquid refrigerant is corrosive to metal surfaces.
Follow the operating instructions supplied
with the service equipment being used.
- Never add R-12 to a refrigerant system
designed to use R-134a. Damage to the system will
result.
- R-12 refrigerant oil must not be mixed with
R-134a refrigerant oil. They are not compatible.
- Do not use R-12 equipment or parts on the
R-134a system. Damage to the system will result.
- Do not overcharge the refrigerant system. This
will cause excessive compressor head pressure
and can cause noise and system failure.
- Recover the refrigerant before opening any fitting
or connection. Open the fittings with caution,
even after the system has been discharged. Never
open or loosen a connection before recovering the
refrigerant.
- Do not remove the secondary retention clip
from any spring-lock coupler connection while the
refrigerant system is under pressure. Recover the
refrigerant before removing the secondary retention
clip. Open the fittings with caution, even after the
system has been discharged. Never open or loosen
a connection before recovering the refrigerant.
- The refrigerant system must always be evacuated
before charging.
- Do not open the refrigerant system or uncap a
replacement component until you are ready to service
the system. This will prevent contamination in
the system.
- Before disconnecting a component, clean the
outside of the fittings thoroughly to prevent contamination
from entering the refrigerant system.
- Immediately after disconnecting a component
from the refrigerant system, seal the open fittings
with a cap or plug.
- Before connecting an open refrigerant fitting,
always install a new seal or gasket. Coat the fitting
and seal with clean refrigerant oil before connecting.
- Do not remove the sealing caps from a replacement
component until it is to be installed.
- When installing a refrigerant line, avoid sharp
bends that may restrict refrigerant flow. Position the
refrigerant lines away from exhaust system components
or any sharp edges, which may damage the
line.
- Tighten refrigerant fittings only to the specified
torque. The aluminum fittings used in the refrigerant
system will not tolerate overtightening.
- Refrigerant oil will absorb moisture from the
atmosphere if left uncapped. Do not open a container
of refrigerant oil until you are ready to use it.
Replace the cap on the oil container immediately after using. Store
refrigerant oil only in a clean, airtight,
and moisture-free container.
- Keep service tools and the work area clean.
Contamination of the refrigerant system through
careless work habits must be avoided.
COOLING SYSTEM REQUIREMENTS
To maintain the performance level of the heatingair
conditioning system, the engine cooling system
must be properly maintained. The use of a bug
screen is not recommended. Any obstructions in front
of the radiator or condenser will reduce the performance
of the air conditioning and engine cooling systems.
The engine cooling system includes the heater core
and the heater hoses. Refer to Group 7 - Cooling System
for more information before the opening of, or
attempting any service to the engine cooling system.
REFRIGERANT HOSES/LINES/TUBES
PRECAUTIONS
Kinks or sharp bends in the refrigerant plumbing
will reduce the capacity of the entire system. High
pressures are produced in the system when it is operating.
Extreme care must be exercised to make sure
that all refrigerant system connections are pressure
tight.
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. Sharp bends will reduce the
flow of refrigerant. The flexible hose lines should be
routed so they are at least 80 millimeters (3 inches)
from the exhaust manifold. It is a good practice to
inspect all flexible refrigerant system hose lines at
least once a year to make sure they are in good condition
and properly routed.
There are two types of refrigerant fittings:
- All fittings with O-rings need to be coated with
refrigerant oil before installation. Use only O-rings
that are the correct size and approved for use with
R-134a refrigerant. Failure to do so may result in a
leak.
- Unified plumbing connections with gaskets cannot
be serviced with O-rings. The gaskets are not
reusable and new gaskets do not require lubrication
before installing.
Using the proper tools when making a refrigerant
plumbing connection is very important. Improper
tools or improper use of the tools can damage the
refrigerant fittings.
The refrigerant must be recovered completely from
the system before opening any fitting or connection.
Open the fittings with caution, even after the refrigerant
has been recovered. If any pressure is noticed as a fitting is loosened, tighten
the fitting and
recover the refrigerant from the system again.
Do not discharge refrigerant into the atmosphere.
Use an R-134a refrigerant recovery/recycling device
that meets SAE Standard J2210.
The refrigerant system will remain chemically stable
as long as pure, moisture-free R-134a refrigerant
and refrigerant oil is used. Dirt, moisture, or air can
upset this chemical stability. Operational troubles or
serious damage can occur if foreign material is
present in the refrigerant system.
When it is necessary to open the refrigerant system,
have everything needed to service the system
ready. The refrigerant system should not be left open
to the atmosphere any longer than necessary. Cap or
plug all lines and fittings as soon as they are opened
to prevent the entrance of dirt and moisture. All lines
and components in parts stock should be capped or
sealed until they are to be installed.
All tools, including the refrigerant recycling equipment,
the manifold gauge set, and test hoses should
be kept clean and dry. All tools and equipment must
be designed for R-134a refrigerant.
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Service warnings and precautions