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Home >> Dodge and Ram >> 2009 >> Durango 2WD V8-4.7L Flex Fuel >> Repair and Diagnosis >> Heating and Air Conditioning >> Housing Assembly HVAC >> Service and Repair >> Overhaul >> Assembly >> Front HVAC Housing

Front HVAC Housing







ASSEMBLY

CAUTION: Be certain to adjust the refrigerant oil level when servicing the A/C refrigerant system Refrigerant Oil Capacity . Failure to properly adjust the refrigerant oil level will prevent the A/C system from operating as designed and can cause serious A/C compressor damage.

NOTE: When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Capacity .

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

NOTE: Gasoline model shown in illustrations. HEV model similar.






NOTE: Front single zone system shown. Front dual zone system similar.

1. If removed, install the floor distribution duct (5) to the HVAC housing (6)Floor Distribution Duct - Installation.
2. Install the blend-air doors and linkage (1), mode-air door (2), baffle (3) and the duct plate (4) into the lower half of the HVAC housing.





3. Install the A/C evaporator (1) into the lower half of the HVAC housing (2). Make sure that the evaporator drain is clean and unrestricted and that the evaporator insulator (3) is properly installed.





4. If removed, install the mode-air doors into the upper half of the HVAC housing (2).
5. Align the ends of the blend-air door pivot shafts (1) to the openings in the upper half of the HVAC housing and install the upper housing half to the lower housing half.





6. Install the screws (4) that secure the two halves of the HVAC housing (3) together. Tighten the screws to 2.2 Nm (20 in lbs.).
7. Install the HVAC wiring harness (1). Make sure the harness is routed through all wiring retainers.
8. If removed, install the blower motor resistor or power module (2), depending on application.
9. Connect the HVAC wire harness to the blower motor resistor or power module, depending on application.





10. Install the blower motor (2) to the HVAC housing (3) .
11. Connect the HVAC wire harness (1) to the blower motor.





12. Carefully install the heater core (6) into the top of the HVAC housing (3). Make sure that the heater core insulator is properly positioned.
13. Install the two screws (4) that secure the heater core retaining bracket (5) to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.).
14. Install the HVAC housing bracket (2) to the top of HVAC housing.
15. Install the two screws (1) that secure the HVAC housing bracket to the HVAC housing. Tighten the screws to 2.2 Nm (20 in. lbs.).





16. Install the heater core tube retaining bracket (4) to the top of the HVAC housing (2).
17. Install the screw (3) that secures the heater core tube retaining bracket to the HVAC housing. Tighten the screw to 2.2 Nm (20 in. lbs.).
18. Install the foam seal (1) to the flange on the HVAC housing.





19. If equipped with front dual zone automatic temperature control (ATC) system, install the driver side blend door actuator (2), cover and retaining screws (1) onto the bottom of the HVAC housing (3) and connect the HVAC wire harness (4) Blend Door Actuator - Installation.





20. Align the two actuator couplers (1) with the mode-air door pivot shafts and install the couplers into the left side of the HVAC housing. Be sure to install the couplers with the coupler arm located between the two stop tabs on the HVAC housing.





21. Install the blend door actuator (3) and the mode door actuators (4) and retaining screws onto the HVAC housing (5) Blend Door Actuator - Installation and Mode Door Actuator - Installation.
22. Install the evaporator temperature sensor (2) into the top of the HVAC housing.
23. Connect the HVAC wire harness (1) to the evaporator temperature sensor, blend door actuator and the mode door actuators.





24. If removed, install the recirculation door actuator (3) to the air inlet housing (5).
25. Install the air inlet housing onto the top of the HVAC housing (1).
26. Install the screws (4) that secure the air inlet housing to the HVAC housing. Make sure the HVAC wire harness retainer is properly installed.
27. Connect the HVAC wire harness to the recirculation door actuator (3).
28. Install the HVAC housing Front HVAC Housing Installation.
29. If the A/C evaporator is being replaced, add 60 milliliters (2 fluid ounces) of refrigerant oil to the refrigerant system. When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be added to the refrigerant system Refrigerant Oil Capacity. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.

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