Commander 2006-2007

Removal & Installation

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Front



  1. Disconnect the negative battery cable.
  2.  
  3. Drain the engine cooling system.
  4.  
  5. Properly disable the airbag system.
  6.  
  7. If required, disconnect the heater hoses from the heater core tubes in the engine compartment.
  8.  
  9. Remove the instrument panel as follows:
    1. Remove the bolts and remove the driver-s side hush panel.
    2.  
    3. Using a trim stick C-4755 or equivalent, separate the upper clips and rotate the cover down and release the lower hinges at the bottom and remove the opening cover.
    4.  
    5. Remove the three bolts in the lower shroud.
      WARNING
      Use care not to break off the tangs on the shrouds.

    6.  
    7. Then unsnap the lower shroud from the upper shroud.
    8.  
    9. Disconnect the steering column electrical connectors.
      WARNING
      Do not turn the steering wheel more than 90° or damage to the clockspring may occur.

    10.  
    11. Position front wheels in the straight ahead position.
    12.  
    13. Remove the pinch bolt.
    14.  
    15. Remove the column support bolts.
    16.  
    17. Remove the column cross bolt and slide the column downward off the bracket and remove the steering column.
    18.  
    19. Remove the nuts attaching the instrument panel to the pedal support bracket.
    20.  
    21. Separate the door seal as necessary to access the side covers.
    22.  
    23. Using a trim stick C-4755 or equivalent, remove the left side cover.
    24.  
    25. Remove the left side door sill trim.
    26.  
    27. Remove the driver-s side cowl trim panel.
    28.  
    29. Disconnect the electrical connectors.
    30.  
    31. Remove the bolts and disconnect the ground wires within the steering column opening to the left of the steering column.
    32.  
    33. Disconnect the white adjustable pedal electrical connector.
    34.  
    35. Disconnect the HVAC electrical connector.
    36.  
    37. Remove the bolts and remove the left a-pillar trim.
    38.  
    39. Remove the two left side bolts and one screw at the a-pillar support.
    40.  
    41. Using a trim stick C-4755 or equivalent, remove the shifter bezel ring.
    42.  
    43. Using a trim stick C-4755 or equivalent, remove the shifter bezel.
    44.  
    45. Remove the center console back cover and disconnect the electrical connector.
    46.  
    47. Remove the screws and remove the console.
    48.  
    49. Disconnect the electrical connectors under the console.
    50.  
    51. Separate the wire harness push pin hangers and remove the screw and disconnect the ground.
    52.  
    53. Remove the shifter assembly.
    54.  
    55. Remove the center HVAC duct.
    56.  
    57. Separate the glove box damper rod from the clove box by sliding the rod towards the rear of the vehicle to release it from the bin.
    58.  
    59. Open the glove box and push the stop tabs down to drop the glove box out of the instrument panel.
    60.  
    61. Rotate the box down and release the door hinges at the bottom and remove the glove box.
    62.  
    63. Remove the passenger side hush panel.
    64.  
    65. Remove the right side door sill trim.
    66.  
    67. Remove the nut , separate the right cowl trim panel and remove.
    68.  
    69. Separate the door seal as necessary to access the side covers.
    70.  
    71. Remove the right side end cap.
    72.  
    73. Disconnect the electrical connectors.
    74.  
    75. Disconnect the antenna cable (1 and 2).
    76.  
    77. Remove the bolts and remove the right a-pillar trim panel.
    78.  
    79. Remove the two right side bolts and one screw at the a-pillar support.
    80.  
    81. Using a trim stick C-4755 or equivalent, remove the defroster grill.
    82.  
    83. Using a trim stick C-4755 or equivalent, remove the radio bezel.
    84.  
    85. Remove the screw inside the lower storage bin, if equipped.
    86.  
    87. Using a trim stick C-4755 or equivalent, remove the center bezel and disconnect the electrical connectors.
    88.  
    89. Remove the nut from the HVAC support stud behind the center bezel.
    90.  
    91. Remove the screw to the HVAC from under the glove box opening.
    92.  
    93. Remove the HVAC bracket bolt from the glove box opening.
    94.  
    95. Remove the left and right center support brackets. * Left side shown, right side similar.
    96.  
    97. Remove the center floor duct.
    98.  
    99. Remove the radio.
    100.  
    101. Remove the two HVAC bolts from the radio opening.
    102.  
    103. Remove the instrument panel assembly
    104.  

  10.  
  11. Remove the five bolts that secure the heater core and tube cover to the HVAC housing.
  12.  
  13. Remove the heater core and tube cover from the HVAC housing.
  14.  
  15. If equipped with dual zone heating-A/C, remove the blend door actuator from the passenger side of the HVAC air distribution housing.
  16.  
  17. Remove the bolt that secure the heater core tubes and retaining bracket to the HVAC housing.
    WARNING
    Protect the carpeting from engine coolant have absorbent towels readily available to clean up any spills.

  18.  
  19. Remove the bolt that secures the heater tubes to the heater core.
  20.  
  21. Disconnect the heater core tubes from the heater core and remove and discard the O-ring seals.
  22.  
  23. Cap the opened heater core ports.
  24.  
  25. Carefully pull the heater core out of the HVAC air distribution housing.

    Click image to see an enlarged view

    Fig. Remove the bolts (1) that secure the heater core cover (2) to the HVAC housing (3)-Front heater core removal



    Click image to see an enlarged view

    Fig. Remove the blend door actuator (1) form the air distribution housing (2). Remove the screws (3) that hold the heater core tubes (4) and bracket (5) to the HVAC housing (6). Remove the bolt (7) that secures the tubes to heater core (8)-Front heater core removal

  26.  

To install:

  1. Carefully install the heater core into the passenger side of the HVAC air distribution housing.
  2.  
  3. Remove the caps from the heater core ports.
  4.  
  5. If removed, position the heater core tubes (4) into the vehicle.
  6.  
  7. Lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tubes.
    WARNING
    Use only the specified O-ring as they are made of a special material for the engine cooling system.

  8.  
  9. Connect the heater core tubes to the heater core.
  10.  
  11. Install the bolt that secures the heater core tubes to the heater core. Tighten the bolt securely.
  12.  
  13. Install the screw that secures the heater core tube retaining bracket to the HVAC housing and tighten to 20 inch lbs. (2.2 Nm).
  14.  
  15. If equipped with dual zone heating-A/C, install the blend door actuator onto the passenger side of the HVAC air distribution housing.
  16.  
  17. Install the heater core and tube cover onto the HVAC housing.
  18.  
  19. Install the five screws that secure the heater core and tube cover to the HVAC housing and tighten to 20 inch lbs. (2.2 Nm).
  20.  
  21. The remainder of the installation is the reverse order of removal.
  22.  
  23. If the heater core is being replaced, flush the cooling system.
  24.  
  25. Refill the engine with coolant to the correct level.
  26.  

Rear



  1. Remove the rear HVAC housing.
  2.  
  3. Carefully remove the foam seal from the flange located at the bottom of the rear HVAC housing.
    NOTE
    If the seal is deformed or damaged, it must be replaced.

  4.  
  5. Partially bend the inner half of the flange downward and remove the heater core tubes from the flange.
  6.  
  7. Release the two tabs that secure the rear heater core in the rear HVAC housing.
  8.  
  9. Carefully pull the rear heater core out of the end of the rear HVAC housing.
    NOTE
    If the foam seals on the heater core are deformed or damaged, they must be replaced.



    Click image to see an enlarged view

    Fig. Remove the foam seal (1) from the flange (2) on the rear HVAC housing (3). Remove the heater core tubes (4) from the flange-Rear heater core removal



    Click image to see an enlarged view

    Fig. Release the tabs (1) that secure the heater core (2) in the HVAC housing (3)-Rear heater core removal

  10.  

To install:

  1. Install the rear heater core into the end of the rear HVAC housing. Make sure that the foam seals are properly installed and that the two retaining tabs are fully engaged.
  2.  
  3. If the rear heater core tubes were removed from the heater core, lubricate new rubber O-ring seals with clean engine coolant and install them onto the heater core tubes. Connect the heater core tubes to the heater core and install two retaining clamps securely.
    WARNING
    Use only the specified O-ring as they are made of a special material for the engine cooling system.

  4.  
  5. Partially bend the inner half of the flange located at the bottom of the rear HVAC housing downward and install the heater core tubes into the flange.
  6.  
  7. Install the foam seal onto the flange.
    NOTE
    If the seal is deformed or damaged, it must be replaced.

  8.  
  9. Install the rear HVAC housing.
  10.  

 
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