Dakota, 2001-2005

Removal & Installation

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2.5L, 3.9L & 5.9L Engines



  1. Recover the refrigerant from the refrigerant system.
  2.  
  3. Disconnect and isolate the battery negative cable.
  4.  
  5. Remove the serpentine drive belt.
  6.  
  7. Unplug the compressor clutch coil wire harness connector.
  8.  
  9. Remove the suction and discharge refrigerant line manifold from the compressor.
  10.  
  11. Install plugs in, or tape over, all the opened refrigerant fittings.
  12.  
  13. Remove the bolts that secure the compressor to the mounting bracket.
  14.  
  15. Remove the compressor from the mounting bracket.

    Click image to see an enlarged view

    Fig. Compressor mounting detail-2.5L Engine



    Click image to see an enlarged view

    Fig. Compressor mounting detail, typical-3.9L and 5.9L Engine

  16.  

To install:

  1. Install the compressor to the mounting bracket and tighten the mounting bolts to 27 Nm (20 ft. lbs.)
  2.  
  3. Remove the tape or plugs from all the opened refrigerant line fittings and install the suction and discharge line manifold to the compressor.
  4.  
  5. Install the serpentine drive belt.
  6.  
  7. Plug in the compressor clutch coil wire harness connector.
  8.  
  9. Connect the battery negative cable.
  10.  
  11. Evacuate the refrigerant system.
  12.  
  13. Charge the refrigerant system.
  14.  

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 serpentine drive belt.
  6.  
  7. Disconnect the A/C compressor clutch coil wire harness connector.
  8.  
  9. Remove the nuts that secure the suction and discharge line fittings to the A/C compressor.
  10.  
  11. Disconnect the suction and discharge line fittings from the A/C compressor.
  12.  
  13. Remove the O-ring seals from the suction and discharge line fittings and discard.
  14.  
  15. Install plugs in, or tape over, all the opened refrigerant line fittings and the compressor ports.
    NOTE
    : Some models are equipped with an A/C support bracket that secures the front of the A/C compressor to the engine front cover.

  16.  
  17. Remove the bolts that secure the A/C compressor to the mounting and support brackets.
  18.  
  19. Remove the A/C compressor from the engine compartment.

    Click image to see an enlarged view

    Fig. Compressor mounting detail, typical-3.7L, 4.7L Engine. Refer to text for parts identification during installation.

  20.  

To install:


NOTE
: Refer to illustration for parts identification during installation.

  1. Install the A/C compressor onto the mounting and support brackets.
  2.  
  3. Install and tighten the bolts in the following sequence:

    If removed, install the bolt that secures the compressor support bracket to the engine front cover and hand tightened.
     
    Install the inner front bolt #3 and hand tighten.
     
    Install the outer front bolt #2 and hand tighten.
     
    Install the rear bolt #1 and hand tighten.
     
    Tighten the inner front bolt #3 to 54 Nm (40 ft. lbs.).
     
    Tighten the outer front bolt #2 to 54 Nm (40 ft. lbs.).
     
    Tighten the rear bolt #1 to 40.5 Nm (30 ft. lbs.).
     
    If removed, tighten the compressor support bracket bolt to the engine front cover to 54 Nm (40 ft. lbs.).
     

  4.  
  5. Remove the tape or plugs from the opened refrigerant line fittings and compressor ports.
  6.  
  7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on the suction and discharge line fittings.
    NOTE
    : Use only the specified O-rings 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.

  8.  
  9. Install the suction and discharge line fittings onto the compressor.
  10.  
  11. Install the nuts that secure the suction and discharge line fittings to the compressor and tighten to 28 Nm (20 ft. lbs.).
  12.  
  13. Connect the wire harness connector to the compressor clutch coil.
  14.  
  15. Install the serpentine drive belt.
  16.  
  17. Reconnect the negative battery cable.
  18.  
  19. Evacuate the refrigerant system.
  20.  
  21. Charge the refrigerant system.
  22.  

  1. Recover the refrigerant from the refrigerant system.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Remove the resonator from the engine.
  6.  
  7. Remove the serpentine drive belt.
  8.  
  9. Disconnect the wire harness connector from the A/C compressor clutch coil.
  10.  
  11. Remove the nuts that secure the A/C suction line and A/C discharge line to the A/C compressor.
  12.  
  13. Disconnect the A/C suction and discharge lines from the A/C compressor and remove and discard the O-ring seals and gaskets.
  14.  
  15. Install plugs in, or tape over, all the opened refrigerant line fittings and the compressor ports.
  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. Compressor mounting detail, typical-2005 Models w/3.7L, 4.7L Engine. Refer to text for parts identification during installation.

  22.  

To install:


NOTE
: Refer to illustration for parts identification during installation.

  1. Position the A/C compressor (2) onto the accessory mounting bracket (4).
  2.  
  3. Install and tighten the bolts in the following sequence:

    Install bolt #3 and hand tighten.
     
    Install bolt #6 and hand tighten.
     
    Install bolt #1 and hand tighten.
     
    Tighten bolt #3 to 40 Nm (30 ft. lbs.).
     
    Tighten bolt #6 to 55 Nm (41 ft. lbs.).
     
    Tighten bolt #1 to 55 Nm (41 ft. lbs.).
     
    Tighten bolt #5 to 55 Nm (41 ft. lbs.).
     

  4.  
  5. Remove the tape or plugs from the opened A/C suction line (2) and the A/C discharge line (3) and the A/C compressor (4).
  6.  
  7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the suction and the discharge line fittings.
    NOTE
    : Use only the specified O-rings 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.

  8.  
  9. Connect the A/C suction and discharge lines onto the A/C compressor.
  10.  
  11. Install the nuts (1) that secure the A/C suction and discharge lines to the A/C compressor and tighten to 23 Nm (17 ft. lbs.).
  12.  
  13. Connect the wire harness connector to the A/C compressor clutch coil.
  14.  
  15. Install the serpentine drive belt.
  16.  
  17. Install the resonator onto the engine.
  18.  
  19. Reconnect the negative battery cable.
  20.  
  21. Evacuate the refrigerant system.
  22.  
  23. Charge the refrigerant system.
  24.  

 
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