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HVAC - Airflow Distribution - Front: Removal & Installation Dodge Durango II

Automatic HVAC System 19 illustrations ~1697 words

REMOVAL

Note. Take the proper precautions to protect the front face of the instrument panel from cosmetic damage.

Scheme 359

Scheme 359: REMOVAL
Scheme 359: REMOVAL

Scheme 360

Scheme 360
Scheme 360
  1. Remove the instrument panel and place it on a workbench (Refer to «ASSEMBLY-INSTRUMENT PANEL»(ref-212841-S41548306542005122700000) ).
  2. Remove the two screws (1) that secure the defroster duct (2) to the top of the instrument panel (3).
  3. Remove the two screws (1) that secure the defroster duct (2) to the demister center duct (3).
  4. Remove the defroster duct from the instrument panel (4).

Scheme 361

Scheme 361: INSTALLATION
Scheme 361: INSTALLATION

Scheme 362

Scheme 362
Scheme 362
  1. Position the defroster duct into the instrument panel.
  2. Install the two screws that secure the defroster duct to the demister center duct. Tighten the screws to 2 N.m (17 in. lbs.).
  3. Install the two screws that secure the defroster duct to the top of the instrument panel. Tighten the screws to 2 N.m (17 in. lbs.).
  4. Install the instrument panel (Refer to «ASSEMBLY-INSTRUMENT PANEL»(ref-212841-S41548306542005122700000) ).

Scheme 363

Scheme 363: FRONT FLOOR DISTRIBUTION DUCT
Scheme 363: FRONT FLOOR DISTRIBUTION DUCT
  1. Remove the HVAC Housing (Refer to «REMOVAL»(ref-212853-S34186963672005122700000) ).
  2. Remove the six screws (1) that secure the front floor distribution duct (2) to the bottom of the HVAC housing (3).
  3. Remove the front floor distribution duct from the HVAC housing.

Scheme 364

Scheme 364: INTERMEDIATE FLOOR DISTRIBUTION DUCTS
Scheme 364: INTERMEDIATE FLOOR DISTRIBUTION DUCTS
  1. Remove the center floor console (Refer to «CONSOLE-FLOOR»(ref-212842-S33575555642005122700000) ).
  2. Remove the front seats (Refer to «SEAT-FRONT»(ref-212844-S26222341092005122700000) ).
  3. Roll back the front floor carpet from under the instrument panel toward the rear of the vehicle (Refer to «CARPET»(ref-212842-S00405069832005122700000) ).
  4. Remove the two push pin fasteners (1) that secure the right intermediate floor distribution duct (2) and the left intermediate floor distribution duct (3) to the floor support (4).
  5. Disconnect the left intermediate floor distribution duct from the front floor distribution duct (5).
  6. If required, disconnect the right intermediate floor distribution duct from the left intermediate floor distribution duct.

Scheme 365

Scheme 365: FRONT FLOOR DISTRIBUTION DUCT
Scheme 365: FRONT FLOOR DISTRIBUTION DUCT
  1. Position the front floor distribution duct (2) to the bottom of the HVAC housing (3).
  2. Install the six screws (1) that secure the front floor distribution duct to the HVAC housing. Tighten the screws to 2 N.m (17 in. lbs.).
  3. Install the HVAC housing (Refer to «INSTALLATION»(ref-212853-S09428561812005122700000) ).

Scheme 366

Scheme 366: INTERMEDIATE FLOOR DISTRIBUTION DUCTS
Scheme 366: INTERMEDIATE FLOOR DISTRIBUTION DUCTS
  1. If removed, connect the right intermediate floor distribution duct to the left intermediate floor distribution duct.
  2. Connect the left intermediate floor distribution duct to the front floor distribution duct.
  3. Install the two push-pin fasteners that secure the intermediate floor distribution ducts to the floor support.
  4. Install the carpet onto the front floor panel and under the instrument panel (Refer to «CARPET»(ref-212842-S00405069832005122700000) ).
  5. Install the front seats (Refer to «SEAT-FRONT»(ref-212844-S26222341092005122700000) ).
  6. Install the center floor console (Refer to «CONSOLE-FLOOR»(ref-212842-S33575555642005122700000) ).

Note. Take the proper precautions to protect the front face of the instrument panel from cosmetic damage.

Scheme 367

Scheme 367: REMOVAL
Scheme 367: REMOVAL
  1. Remove the instrument panel and place it on a workbench (Refer to «ASSEMBLY-INSTRUMENT PANEL»(ref-212841-S41548306542005122700000) ).
  2. Remove the instrument cluster (Refer to «CLUSTER»(ref-212788-S26038242652005122700000) ).
  3. Remove the radio and reinforcement bracket (Refer to «RADIO»(ref-212755-S16893023632005122700000) ).
  4. Remove the instrument panel speakers (Refer to «SPEAKER»(ref-212755-S22499496792005122700000) ).
  5. Remove the passenger side air bag (1) (Refer to «AIR BAG RESTRAINT SYSTEMS»(ref-170504) ).
  6. Remove the defroster duct (2) (Refer to «REMOVAL»(ref-212853-S28243728282005122700000) ).
  7. Remove the demister air outlets (Refer to «REMOVAL - DEMISTER OUTLETS»(ref-212853-S27477440972005122700000) ).
  8. Remove the instrument panel top cover (3) (Refer to «GRILLE-DEFROSTER»(ref-212841-S03506255932005122700000) ).
  9. Remove the park brake release handle assembly from the instrument panel.
  10. Remove the instrument panel reinforcement (4).
  11. Remove the passenger side demister outlet duct (5).
  12. Remove the passenger side demister duct (6).
  13. Remove the instrument panel ducts (7) (Refer to «REMOVAL»(ref-212853-S22890070772005122700000) ).

Scheme 368

Scheme 368: INSTALLATION
Scheme 368: INSTALLATION
  1. Install the instrument panel ducts (7)
  2. Install the passenger side demister duct (6).
  3. Install the passenger side demister outlet duct (5).
  4. Install the instrument panel reinforcement (4).
  5. Install the park brake release handle assembly.
  6. Install the instrument panel top cover (3) (Refer to «GRILLE-DEFROSTER»(ref-212841-S03506255932005122700000) ).
  7. Install the demister air outlets (Refer to «INSTALLATION - DEMISTER OUTLETS»(ref-212853-S20802756652005122700000) )..
  8. Install the defroster duct (2) (Refer to «INSTALLATION»(ref-212853-S32646805862005122700000) ).
  9. Install the passenger side air bag (1) (Refer to «AIR BAG RESTRAINT SYSTEMS»(ref-170504) ).
  10. Install the instrument panel speakers (Refer to «SPEAKER»(ref-212755-S22499496792005122700000) ).
  11. Install the radio and reinforcement bracket (Refer to «RADIO»(ref-212755-S16893023632005122700000) ).
  12. Install the instrument cluster (Refer to «CLUSTER»(ref-212788-S26038242652005122700000) ).
  13. Install the instrument panel (Refer to «ASSEMBLY-INSTRUMENT PANEL»(ref-212841-S41548306542005122700000) ).

Note. Take the proper precautions to protect the front face of the instrument panel from cosmetic damage.

Scheme 369

Scheme 369: REMOVAL
Scheme 369: REMOVAL
  1. Remove the instrument panel and place it on a workbench (Refer to «ASSEMBLY-INSTRUMENT PANEL»(ref-212841-S41548306542005122700000) ).
  2. Remove the instrument cluster (Refer to «CLUSTER»(ref-212788-S26038242652005122700000) ).
  3. Remove the radio and reinforcement bracket (Refer to «RADIO»(ref-212755-S16893023632005122700000) ).
  4. Remove the instrument panel speakers (Refer to «SPEAKER»(ref-212755-S22499496792005122700000) ).
  5. Remove the passenger side air bag (1) (Refer to «AIR BAG RESTRAINT SYSTEMS»(ref-170504) ).
  6. Remove the defroster duct (2) (Refer to «REMOVAL»(ref-212853-S28243728282005122700000) ).
  7. Remove the demister air outlets (Refer to «REMOVAL - DEMISTER OUTLETS»(ref-212853-S27477440972005122700000) ).
  8. Remove the instrument panel top cover (3) (Refer to «GRILLE-DEFROSTER»(ref-212841-S03506255932005122700000) ).
  9. Remove the park brake release handle assembly from the instrument panel.
  10. Remove the instrument panel reinforcement (4).
  11. Remove the passenger side demister outlet duct (5).
  12. Remove the passenger side demister duct (6).
  13. Remove the instrument panel ducts (7) (Refer to «REMOVAL»(ref-212853-S22890070772005122700000) ).
  14. Remove the driver side demister duct (8).

Scheme 370

Scheme 370: INSTALLATION
Scheme 370: INSTALLATION
  1. Install the driver side demister duct (8).
  2. Install the instrument panel ducts (7)
  3. Install the passenger side demister duct (6).
  4. Install the passenger side demister outlet duct (5).
  5. Install the instrument panel reinforcement (4).
  6. Install the park brake release handle assembly.
  7. Install the instrument panel top cover (3) (Refer to «GRILLE-DEFROSTER»(ref-212841-S03506255932005122700000) ).
  8. Install the demister air outlets (Refer to «INSTALLATION - DEMISTER OUTLETS»(ref-212853-S20802756652005122700000) )..
  9. Install the defroster duct (2) (Refer to «INSTALLATION»(ref-212853-S32646805862005122700000) ).
  10. Install the passenger side air bag (1) (Refer to «AIR BAG RESTRAINT SYSTEMS»(ref-170504) ).
  11. Install the instrument panel speakers (Refer to «SPEAKER»(ref-212755-S22499496792005122700000) ).
  12. Install the radio and reinforcement bracket (Refer to «RADIO»(ref-212755-S16893023632005122700000) ).
  13. Install the instrument cluster (Refer to «CLUSTER»(ref-212788-S26038242652005122700000) ).
  14. Install the instrument panel (Refer to «ASSEMBLY-INSTRUMENT PANEL»(ref-212841-S41548306542005122700000) ).

Scheme 371

Scheme 371: DESCRIPTION
Scheme 371: DESCRIPTION

All models are equipped with a common HVAC housing (9) that combines A/C and heating capabilities into a single unit mounted within the passenger compartment. The heating-A/C system is a blend-air type system. The blend-air doors (11) control the amount of conditioned air that is allowed to flow, through, or around, the heater core (14). The A/C system is designed for the use of a non-CFC, R-134a refrigerant and uses an A/C evaporator (5) to cool and dehumidify the incoming air prior to blending it with the heated air. A temperature control determines the discharge air temperature by operating the blend door actuator (4), which moves the blend-air doors. This allows an almost immediate control of the output air temperature of the system. The mode door actuators (12) operates the mode-air doors (10 and 13) which direct the flow of the conditioned air out the various air outlets, depending on the mode selected. The recirculation door actuator (3) operates the recirculation-air door (2) which closes off the fresh air intake and recirculates the air already inside the vehicle. The electric actuators are connected to the vehicle electrical system by the HVAC wire harness (1). The blower motor (8) controls the velocity of air flowing through the HVAC housing by spinning the blower wheel (6) within the HVAC housing at the selected speed by use of the blower motor resistor block or power model (7), depending on application.

The front HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, recirculation-air door, mode-air doors, blend-air doors and linkage.

WARNINGRefer to the applicable warnings and cautions for this system before performing the following operation (Refer to WARNING ) and (Refer to CAUTION - A/C SYSTEM ). Failure to follow the warnings and cautions could result in possible personal injury or death.
WARNINGOn vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental air-bag deployment and possible personal injury or death.

Note. The front HVAC housing must be removed from the vehicle and disassembled for service of the A/C evaporator, recirculation-air door, mode-air doors, blend-air doors and linkage.

Scheme 372

Scheme 372
Scheme 372

Scheme 373

Scheme 373
Scheme 373
  1. Recover the refrigerant from the refrigerant system (Refer to «REFRIGERANT SYSTEM RECOVERY»(ref-212855-S22954270352005122700000) ).
  2. Drain the engine cooling system (Refer to «DRAINING COOLING SYSTEM - ALL ENGINES»(ref-212747-S18408552002005122700000) ).
  3. Disconnect and isolate the negative battery cable.
  4. Disconnect the liquid line and suction line from the expansion valve and install plugs or caps over the fittings and expansion valve ports(Refer to «LINE-A/C LIQUID»(ref-212855-S20817824442005122700000) ).
  5. Disconnect the heater hoses from the heater core tubes and install plugs or caps over the heater core tube openings.
  6. Remove the four nuts (1) that secure the HVAC housing (2) to the engine compartment side of the dash panel (3).
  7. Remove the instrument panel from the passenger compartment (Refer to «ASSEMBLY-INSTRUMENT PANEL»(ref-212841-S41548306542005122700000) ).
  8. Disconnect the intermediate floor distribution duct from the front floor distribution duct.
  9. Remove the two bolts (1) that secure the HVAC housing (2) to the passenger compartment side of the dash panel (3).
  10. Pull the HVAC housing rearward so that the mounting studs and condensate drain tube clear the dash panel and remove the front HVAC housing from the passenger compartment.
WARNINGOn vehicles equipped with airbags, disable the airbag system before attempting any steering wheel, steering column, or instrument panel component diagnosis or service. Disconnect and isolate the battery negative (ground) cable, then wait two minutes for the airbag system capacitor to discharge before performing further diagnosis or service. This is the only sure way to disable the airbag system. Failure to take the proper precautions could result in accidental air-bag deployment and possible personal injury or death.

Scheme 374

Scheme 374
Scheme 374
  1. Disconnect and isolate the negative battery cable.
  2. Remove the right front door sill trim panel (Refer to «PLATE-DOOR SCUFF»(ref-212842-S33769523622005122700000) ).
  3. Remove the right side interior cowl trim cover (Refer to «PANEL-COWL SIDE TRIM»(ref-212842-S01653165222005122700000) ).
  4. Disconnect the wire harness connector (1) from the blower motor (2).
  5. Remove the three screws (3) that secure the blower motor and blower wheel assembly to the HVAC housing (4).
  6. Remove the blower motor and blower wheel assembly from the HVAC housing.

Scheme 375

Scheme 375: INSTALLATION
Scheme 375: INSTALLATION
  1. Position the blower motor and blower wheel assembly (2) into the HVAC housing (4).
  2. Install the three screws (3) that secure the blower motor and blower wheel assembly to the HVAC housing. Tighten the screws to 2.2 N.m (20 in. lbs.).
  3. Connect the wire harness connector (1) to the blower motor.
  4. Install the right side interior cowl trim cover (Refer to «PANEL-COWL SIDE TRIM»(ref-212842-S01653165222005122700000) ).
  5. Install the right front door sill trim panel (Refer to «PLATE-DOOR SCUFF»(ref-212842-S33769523622005122700000) ).
  6. Reconnect the negative battery cable.

REMOVAL - DEMISTER OUTLETS

Note. The instrument panel demister outlets are retained into the instrument panel top pad by a light snap fit.

Scheme 376

Scheme 376: REMOVAL - DEMISTER OUTLETS
Scheme 376: REMOVAL - DEMISTER OUTLETS
  1. Using a trim stick or another suitable wide flat-bladed tool, gently pry the instrument panel demister outlet(s) (1) out of the instrument panel top pad (2) as required.

Scheme 377

Scheme 377: INSTALLATION - DEMISTER OUTLETS
Scheme 377: INSTALLATION - DEMISTER OUTLETS
  1. Position the instrument panel demister outlet(s) (1) onto the instrument panel top pad (2).
  2. Gently push the demister outlet(s) into the top pad until it snaps into place.

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