Commander 2006-2007

Removal & Installation

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CAUTION
Refer to the applicable warnings and cautions for this system before performing the following operation.


NOTE
The A/C compressor may be removed and repositioned without disconnecting the refrigerant lines or discharging the refrigerant system. Discharging is not necessary if servicing the compressor clutch, clutch field coil, engine, engine cylinder head or the generator.


NOTE
If an internal failure of the A/C compressor has occurred, the receiver/drier must be replaced.

3.7L & 4.7L Engines



  1. Recover the refrigerant from the refrigerant system.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Remove the resonator from the air cleaner housing and the engine.
  6.  
  7. Remove the accessory drive belt.
  8.  
  9. Remove the nuts that secure the A/C discharge line and the A/C suction line to the A/C compressor.
  10.  
  11. Disconnect the refrigerant lines from the A/C compressor and remove and discard the dual plane seals.
  12.  
  13. Install plugs in, or tape over all of the opened refrigerant line fittings and the compressor ports.

    Click image to see an enlarged view

    Fig. A/C Compressor, discharge line, and suction line-3.7L and 4.7L engines

  14.  
  15. Disconnect the wire harness connector from the A/C compressor.
  16.  
  17. Loosen the bolt that secures the bracket to the accessory mounting bracket.
  18.  
  19. Remove the bolts that secure the A/C compressor to the accessory mounting bracket.
  20.  
  21. Remove the A/C compressor from the engine compartment.

    Click image to see an enlarged view

    Fig. A/C Compressor and bolts-3.7L and 4.7L engines

  22.  

To install:


WARNING
If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level. 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. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.


WARNING
The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver/drier can cause serious damage to the replacement A/C compressor.


NOTE
When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor.


NOTE
Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.

  1. Position the A/C compressor onto the accessory mounting bracket.
  2.  
  3. Install and tighten the bolts in the following sequence:
    1. Install bolt No. 3 and hand tighten.
    2.  
    3. Install bolt No. 6 and hand tighten.
    4.  
    5. Install bolt No. 1 and hand tighten.
    6.  
    7. Tighten bolt No. 3 to 30 ft. lbs. (40 Nm).
    8.  
    9. Tighten bolt No. 6 to 41 ft. lbs. (55 Nm).
    10.  
    11. Tighten bolt No. 1 to 41 ft. lbs. (55 Nm).
    12.  
    13. Tighten bolt No. 5 to 41 ft. lbs. (55 Nm).

      Click image to see an enlarged view

      Fig. A/C Compressor and bolts-3.7L and 4.7L engines

    14.  

  4.  
  5. Connect the wire harness connector to the A/C compressor clutch coil connector.
  6.  
  7. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
  8.  
  9. Lubricate new dual plane seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  10.  
  11. Install the A/C suction line and the A/C discharge line onto the A/C compressor.
  12.  
  13. Install the nuts that secure the refrigerant lines to the A/C compressor. Tighten the nuts to 15 ft. lbs. (20 Nm).

    Click image to see an enlarged view

    Fig. A/C Compressor, discharge line, and suction line-3.7L and 4.7L engines

  14.  
  15. Install the accessory drive belt.
  16.  
  17. Replace the A/C receiver/drier if the A/C compressor is being replaced due to an internal failure.
  18.  
  19. Install the resonator onto the engine and air cleaner housing.
  20.  
  21. Reconnect the negative battery cable.
  22.  
  23. Evacuate the refrigerant system.
  24.  
  25. Charge the refrigerant system.
  26.  

5.7L Engine



  1. Disconnect and isolate the negative battery cable.
  2.  
  3. Recover the refrigerant from the refrigerant system.
  4.  
  5. Remove the resonator from the air cleaner housing and engine.
  6.  
  7. Remove the accessory drive belt.
  8.  
  9. Remove the nuts that secure the A/C discharge line and A/C suction line to the A/C compressor.

    Click image to see an enlarged view

    Fig. A/C Compressor, discharge line, and suction line-5.7L engine

  10.  
  11. Disconnect the refrigerant lines from the A/C compressor and remove and discard the dual plane seals.
  12.  
  13. Install plugs in, or tape over all of the opened refrigerant line fittings and the compressor ports.
  14.  
  15. Remove the three bolts that secure the power steering pump to the engine and position the pump out of the way.
  16.  
  17. Disconnect the wire harness connector from the A/C compressor.
  18.  
  19. Support the A/C compressor and remove the bolts that secure the compressor to the engine.
  20.  
  21. Remove the A/C compressor from the engine compartment.

    Click image to see an enlarged view

    Fig. A/C Compressor, power steering pump, and bolts-5.7L engine

  22.  

To install:


WARNING
If the A/C compressor is being replaced, be certain to adjust the refrigerant system oil level. 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. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.


WARNING
The A/C receiver/drier must be replaced if an internal failure of the A/C compressor has occurred. Failure to replace the A/C receiver/drier can cause serious damage to the replacement A/C compressor.


NOTE
When replacing multiple A/C system components, refer to the Refrigerant Oil Capacities chart to determine how much oil should be removed from the new A/C compressor.


NOTE
Replacement of the refrigerant line O-ring seals and gaskets is required anytime a refrigerant line is opened. Failure to replace the rubber O-ring seals and metal gaskets could result in a refrigerant system leak.

  1. If the A/C compressor is being replaced, the refrigerant oil in the old compressor must be first drained and measured. Then the oil in the new A/C compressor must be drained. Finally, the new compressor must be refilled with the same amount of new refrigerant oil that was drained out of the old compressor. 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. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  2.  
  3. Position the A/C compressor into the engine compartment.
  4.  
  5. Install the bolts that secure the A/C compressor to the engine. Tighten the bolts to 41 ft. lbs. (55 Nm).
  6.  
  7. Connect the wire harness connector to the A/C compressor.
  8.  
  9. Position the power steering pump onto the engine.
  10.  
  11. Install the three bolts that secure the power steering pump to the engine. Tighten the bolts securely.

    Click image to see an enlarged view

    Fig. A/C Compressor, power steering pump, and bolts-5.7L engine

  12.  
  13. Remove the tape or plugs from the opened refrigerant line fittings and the compressor ports.
  14.  
  15. Lubricate new dual plane seals with clean refrigerant oil and install them onto the refrigerant line fittings. Use only the specified seals as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  16.  
  17. Install the A/C suction line and the A/C discharge line onto the A/C compressor.
  18.  
  19. Install the nuts that secure the refrigerant lines to the A/C compressor. Tighten the nuts to 15 ft. lbs. (20 Nm).

    Click image to see an enlarged view

    Fig. A/C Compressor, discharge line, and suction line-5.7L engine

  20.  
  21. Install the accessory drive belt.
  22.  
  23. Replace the A/C receiver/drier if the A/C compressor is being replaced due to an internal failure.
  24.  
  25. Install the resonator onto the engine and the air cleaner housing.
  26.  
  27. Reconnect the negative battery cable.
  28.  
  29. Evacuate the refrigerant system.
  30.  
  31. Charge the refrigerant system.
  32.  

 
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