Controls - Front: Removal & Installation Dodge Durango II

REMOVAL

Scheme 304

1. Disconnect and isolate the negative battery cable.
2. Remove the screws (5) that secure the panel door actuator (2) and the floor/defrost door actuator (3) located on the driver side end of the HVAC housing (4) as required.
3. Disconnect the HVAC wire harness connector (1) from the panel door actuator and the floor/defrost door actuator as required.
4. Remove the mode door actuator(s) from the HVAC housing.

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Scheme 306

1. Position the mode door actuator(s) (1) onto the driver side end of the HVAC housing as required. If necessary, rotate the actuator slightly to align the splines on the actuator output shaft with those in the mode-air door linkage.
2. Install the screws (5) that secure the panel door actuator (2) and the floor/defrost door actuator (3) to the HVAC housing (4) as required. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the HVAC wire harness connector (1) to the mode door actuator(s) as required.
4. Reconnect the negative battery cable.
5. Initiate the Actuator Calibration function using a scan tool. Refer to HVAC System Test, found in «HVAC - ELECTRICAL DIAGNOSTICS»(ref-212849) .

Note. The A/C compressor clutch can be serviced in the vehicle. The refrigerant system can remain fully-charged during compressor clutch, pulley and bearing assembly, or coil replacement.

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1. Disconnect and isolate the negative battery cable.
2. Remove the accessory drive belt (Refer to «ACCESSORY DRIVE»(ref-212748) ).
3. Disconnect the engine wire harness connector for the A/C compressor clutch coil from the clutch field coil wire harness connector on the top of the A/C compressor.
4. Remove the bolts that secure the A/C compressor to the engine and support the A/C compressor.
5. Remove the compressor shaft bolt (1). A band-type oil filter wrench or a strap wrench may be used to secure the clutch plate (2) during bolt removal. CAUTION: Do not pry between the clutch plate and the pulley and bearing assembly to remove the clutch plate from the compressor shaft as this may damage the clutch plate. NOTE: Use care not to lose any clutch shim(s) during removal of the clutch plate, as they may be reused during the clutch plate installation process.
6. Tap the clutch plate (2) lightly with a plastic mallet to release it from the splines on the compressor shaft (1). Remove the clutch plate and shim(s) (3) from the compressor shaft.
7. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), remove the external snap ring (1) that secures the pulley and bearing assembly (3) to the front cover of the A/C compressor, then slide the pulley and bearing assembly off of the A/C compressor.
8. Remove the screw that secures the clutch coil pigtail wire connector bracket and ground clip to the top of the compressor housing (3).
9. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), remove the external snap ring (4) that secures the clutch field coil (2) to the front cover of the compressor housing, then slide the clutch field coil off of the A/C compressor.

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1. Align the dowel pin on the back of the clutch field coil (2) with the hole in the compressor front cover (3) and position the clutch field coil onto the A/C compressor. Be certain that the clutch coil wire harness is properly oriented and routed so that it is not pinched between the compressor front cover and the clutch field coil. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the clutch field coil to the A/C compressor. The bevel side of the snap ring must face outward and both snap ring eyelets must be oriented to the right or to the left of the clutch field coil dowel pin location on the A/C compressor.
2. Using snap ring pliers (Special Tool C-4574 or equivalent) (1), install the external snap ring (4) that secures the clutch field coil to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove and oriented correctly.
3. Install the screw that secures the clutch field coil wire harness connector bracket and ground clip to the top of the compressor housing. Tighten the screw securely. CAUTION: When installing the pulley and bearing assembly, DO NOT mar the friction surfaces of the pulley or premature failure of the clutch will result.
4. Install the pulley and bearing assembly (1) onto the front cover of the A/C compressor. If necessary, tap the pulley gently with a block of wood (2) placed on the pulley friction surface. CAUTION: The snap ring must be fully and properly seated in the groove or it will vibrate out, resulting in a clutch failure and severe damage to the A/C compressor. NOTE: A new snap ring must be used to secure the pulley and bearing assembly to the A/C compressor. The bevel side of the snap ring must face outward.
5. Using snap ring pliers (Special Tool C-4574 or equivalent) (2), install the external snap ring (1) that secures the pulley and bearing assembly (3) to the front cover of the A/C compressor. Be certain that the snap ring is fully and properly seated in the groove.
6. If the original clutch plate (2) and pulley and bearing assembly are to be reused, reinstall the original shim(s) (3) on the compressor shaft (1) against the shoulder. If a new clutch plate and/or pulley and bearing assembly are being used, install a trial stack of shims 2.54 mm (0.010 in.) thick on the compressor shaft against the shoulder.
7. Install the clutch plate (2) onto the compressor shaft.
8. Install the compressor shaft bolt (1). Tighten the bolt to 17.5 N.m (155 in. lbs.). NOTE: The shims may compress after tightening the shaft bolt. Check the air gap in four or more places to verify the air gap is correct. Spin the pulley before performing a final check of the air gap.
9. With the clutch plate assembled tight against the shim(s), measure the air gap between the clutch plate and the pulley and bearing assembly faces with a feeler gauge. The air gap should be between specifications (Refer to «SPECIFICATIONS»(ref-212850-S40226965022005122700000) ). If the proper air gap is not obtained, add or subtract shims as needed until the desired air gap is obtained.
10. Install the bolts that secure the A/C compressor to the engine (Refer to «COMPRESSOR-A/C»(ref-212855-S21919888982005122700000) ).
11. Connect the engine wire harness connector to the A/C compressor clutch coil.
12. Install the accessory drive belt (Refer to «ACCESSORY DRIVE»(ref-212748) ).
13. Reconnect the negative battery cable.

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Scheme 317

1. Disconnect and isolate the negative battery cable.
2. Remove the center bezel (1) from the instrument panel, disconnect the wire harness connector(s) (2) from the A/C-heater control (3) and place the center bezel on a workbench (Refer to «BEZEL-CENTER»(ref-212841-S02997476492005122700000) ).
3. Remove the four screws (1) that secure the A/C-heater control (2) to the instrument panel center bezel (3).
4. Remove the A/C-heater control from the instrument panel center bezel.

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Scheme 319

1. Position the A/C-heater control (2) into the instrument panel center bezel (3).
2. Install the screws (1) that secure the A/C-heater control to the instrument panel center bezel. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the wire harness connector(s) (2) to the A/C-heater control (3) and install the instrument panel center bezel (1) (Refer to «BEZEL-CENTER»(ref-212841-S02997476492005122700000) ).
4. Reconnect the negative battery cable.

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Scheme 321

1. Disconnect and isolate the negative battery cable.
2. Remove the two screws (1) that secure the trim cover (2) over the blower motor power module (3) located below the right side of the instrument panel.
3. Remove the trim cover.
4. Disconnect the two wire harness connectors (1) from the blower motor power module (2).
5. Remove the two screws (3) that secure the blower motor power module to the front HVAC housing
6. Remove the blower motor power module from the front HVAC housing.

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Scheme 323

1. Position the blower motor power module (2) into the front HVAC housing (4).
2. Install the two screws (3) that secure the blower motor power module to the front HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the two wire harness connectors (1) to the blower motor power module.
4. Install the trim cover (2) over the blower motor power module (3).
5. Install the two screws (1) that secure the trim cover to the front HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
6. Reconnect the negative battery cable.

INSTALLATION

Note. Refer to the fuse and relay layout map on the inner surface of the PDC cover for A/C clutch relay identification and location.

Scheme 324

1. Position the A/C clutch relay (3) into the proper receptacle of the PDC (1).
2. Align the A/C clutch relay terminals with the terminal cavities in the PDC receptacle and push down firmly on the relay until the terminals are fully seated.
3. Close the PDC cover (2).
4. Reconnect the negative battery cable.

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Scheme 326

1. Disconnect and isolate the negative battery cable.
2. Remove the two screws (1) that secure the trim cover (2) over the blower motor resistor block (3) located below the right side of the instrument panel.
3. Remove the trim cover.
4. Disconnect the wire harness connector (1) from the blower motor resistor block (2).
5. Remove the two screws (3) that secure the blower motor resistor block to the front HVAC housing.
6. Remove the blower motor resistor block from the front HVAC housing.

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Scheme 328

1. Position the blower motor resistor block (2) into the front HVAC housing (4).
2. Install the two screws (3) that secure the blower motor resistor block to the front HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
3. Connect the wire harness connector (1) to the blower motor resistor block.
4. Install the trim cover (2) over the blower motor resistor block.
5. Install the two screws (1) that secure the trim cover to the front HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
6. Reconnect the negative battery cable.

Note. The A/C evaporator has two other locations (besides the original location) provided for the evaporator temperature sensor probe. Use the location (hole) that best provides a secure fit of the probe between the evaporator fins.

Scheme 329

1. Install the probe of the evaporator temperature sensor into one of the holes provided between the fins of the A/C evaporator.
2. Install the grommet (6) into the opening in the HVAC housing (3).
3. Install the evaporator temperature sensor wires (4) into the retainer (5).
4. Connect the HVAC wire harness (1) to the evaporator temperature sensor connector (2).
5. Install the HVAC housing (Refer to «HOUSING-HVAC»(ref-212853-S30259552272005122700000) ).

Note. It is not necessary to discharge the refrigerant system to replace the A/C pressure transducer.

Scheme 330

1. Disconnect and isolate the negative battery cable.
2. Disconnect the wire harness connector (1) from the A/C pressure transducer (2).
3. Remove the A/C pressure transducer from the A/C discharge line (3).
4. Remove the O-ring seal (4) from the discharge line fitting and discard.

Note. Use only the specified O-ring as it is made of special material for R-134a. Use only refrigerant oil of the type required for the A/C compressor.

Scheme 331

1. Lubricate a new rubber O-ring seal (4) with clean refrigerant oil and install it onto the discharge line fitting (3).
2. Install the A/C pressure transducer (2) onto the discharge line fitting. Tighten the A/C pressure transducer securely.
3. Connect the wire harness connector (1) to the A/C pressure transducer.
4. Reconnect the negative battery cable