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Pacifica 2006-2008

Removal & Installation

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3.5L Engine




CAUTION
Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.


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


NOTE
Before removing the A/C condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the A/C condenser and the radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.

  1. Recover the refrigerant from the refrigerant system.
  2.  
  3. Remove the front fascia.
  4.  
  5. Remove the four radiator sight shield retaining pins and the radiator sight shield.
  6.  
  7. Remove the radiator air seal retaining pins and the air seals.
  8.  
  9. Note the hood latch location on the upper radiator crossmember. Mark the location of latch for reinstallation.
  10.  
  11. Remove the two bolts that secure the hood latch to the upper radiator crossmember and position the latch out of the way.
  12.  
  13. Remove the four bolts that secure the transmission fluid oil cooler to the A/C condenser and position the fluid cooler out of the way.
  14.  
  15. Remove the nuts that secure the discharge and liquid lines to the A/C condenser.
  16.  
  17. Disconnect the discharge and liquid lines from the A/C condenser and remove the O-ring seals and gaskets.
  18.  
  19. Install plug in, or tape over the opened refrigerant line fittings and the condenser ports.
  20.  
  21. Remove the two bolts that secure the A/C condenser to the radiator.
  22.  
  23. Lift the A/C condenser and disengage the lower condenser mounting brackets from the radiator.
  24.  
  25. Remove the A/C condenser from the engine compartment.
  26.  

To install:


NOTE
If the A/C condenser is being replaced, add 1 fluid ounce (30 milliliters) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.


NOTE
Be certain that each of the radiator and condenser air seals are reinstalled in their proper locations. These air seals are required in order for the A/C and engine cooling systems to perform as designed.

  1. Position the A/C condenser into the engine compartment.
  2.  
  3. Engage the lower condenser mounting brackets to the radiator.
  4.  
  5. Install the two bolts that secure the A/C condenser to the radiator. Tighten the bolts to 45 inch lbs. (5 Nm).
  6.  
  7. Remove the tape or plug from the opened refrigerant line fittings the condenser ports.
  8.  
  9. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge and liquid line fittings.
  10.  
  11. Connect the discharge and liquid lines to the A/C condenser.
  12.  
  13. Install the nuts that secure the discharge and liquid lines to the A/C condenser. Tighten the nuts to 17 ft. lbs. (23 Nm).
  14.  
  15. Position the transmission fluid oil cooler onto the A/C condenser and install the four retaining bolts. Tighten the bolts to 45 inch lbs. (5 Nm).
  16.  
  17. Position the hood latch to the front of the upper radiator crossmember.
  18.  
  19. Loosely install the two bolts that secure the hood latch to the upper radiator crossmember. Check and adjust the hood latch position as required. Tighten the bolts to 123 inch lbs. (14 Nm).
  20.  
  21. Install the radiator air seals and the air seal retaining pins.
  22.  
  23. Install the radiator sight shield and the sight shield retaining pins.
  24.  
  25. Install the front fascia.
  26.  
  27. Evacuate the refrigerant system.
  28.  
  29. Charge the refrigerant system.
  30.  

3.8L & 4.0L Engines




CAUTION
Refer to the applicable warnings and cautions for this system before performing the following operation. Failure to follow the warnings and cautions could result in possible personal injury or death.


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


NOTE
Before removing the A/C condenser, note the location of each of the radiator and condenser air seals. These seals are used to direct air through the A/C condenser and the radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.

  1. Recover the refrigerant from the refrigerant system.
  2.  
  3. Disconnect and isolate the negative battery cable.
  4.  
  5. Remove the radiator closure panel.
  6.  
  7. Remove the front fascia.
  8.  
  9. Remove the retaining pins that secure the radiator end air seals to the front of the A/C condenser and remove the air seals.
  10.  
  11. Disconnect the wire harness connector from the ambient temperature sensor located on the left side of the A/C condenser.
  12.  
  13. Remove the push-pin retainer that secures the ambient temperature sensor to the A/C condenser and remove the sensor.
  14.  
  15. Disconnect the automatic transmission cooler lines from the transmission fluid cooler portion of the A/C condenser.
  16.  
  17. Install plugs in, or tape over the opened automatic transmission cooler line fittings and cooler ports.
  18.  
  19. Remove the bolt that secures the left side of the A/C condenser to the radiator.

    Click image to see an enlarged view

    Fig. A/C Condenser-3.8L and 4.0L Engines

  20.  
  21. Remove the nut that secures the A/C discharge line to the right side of the A/C condenser.
  22.  
  23. Disconnect the A/C discharge line from the A/C condenser and remove and discard the O-ring seal and gasket.
  24.  
  25. Remove the bolt that secures the right side of the A/C condenser to the radiator.

    Click image to see an enlarged view

    Fig. Condenser and discharge line-3.8L and 4.0L Engines

  26.  
  27. Remove the nut that secures the A/C liquid line to the right side of the A/C condenser.
  28.  
  29. Install plugs in, or tape over the opened refrigerant line fittings and condenser ports.
  30.  
  31. Partially lift the A/C condenser to disengage each lower condenser bracket from the mounting tab located on each end of the radiator.
  32.  
  33. Carefully tilt the bottom of the A/C condenser forward and lower the condenser out from the front of the engine compartment.
  34.  

To install:


WARNING
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.


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.


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. Carefully position the A/C condenser upward into the front of the engine compartment and engage each lower condenser bracket to the mounting tab located on each end of the radiator.
  2.  
  3. Remove the tape or plugs from the opened refrigerant line fittings and condenser ports.
  4.  
  5. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the liquid line fitting. Use only the specified O-ring seal as it is 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.
  6.  
  7. Connect the A/C liquid line to the A/C condenser and install the retaining nut. Tighten the nut to 17 ft. lbs. (23 Nm).
  8.  
  9. Install the bolt that secures the right side of the A/C condenser to the radiator. Tighten the bolt to 45 inch lbs. (5 Nm).
  10.  
  11. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it and a new gasket onto the discharge line fitting. Use only the specified O-ring seal as it is 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.
  12.  
  13. Connect the A/C discharge line to the A/C condenser and install the retaining nut . Tighten the nut to 17 ft. lbs. (23 Nm).
  14.  
  15. Install the bolt that secures the left side of the A/C condenser to the radiator. Tighten the bolt to 45 inch lbs. (5 Nm).
  16.  
  17. Remove the tape or plugs from the opened transmission cooler line fittings and cooler ports.
  18.  
  19. Connect the automatic transmission cooler lines to the transmission fluid cooler portion of the A/C condenser.
  20.  
  21. Position the ambient temperature sensor to the A/C condenser and install the push-pin retainer.
  22.  
  23. Connect the wire harness connector to the ambient temperature sensor.
    NOTE
    Be certain that each of the radiator and condenser air seals are installed in their proper locations. These air seals are required for the A/C and engine cooling systems to perform as designed.

  24.  
  25. Position the radiator end air seals to the front of the A/C condenser and install the retaining pins.
  26.  
  27. Install the front fascia.
  28.  
  29. Install the radiator closure panel.
  30.  
  31. Reconnect the negative battery cable.
  32.  
  33. Evacuate the refrigerant system.
  34.  
  35. If the A/C condenser is being replaced, add 2 fluid ounces (60 milliliters) 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. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.
  36.  
  37. Charge the refrigerant system.
  38.  
  39. Check the automatic transmission fluid level.
  40.  

 
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