Condenser HVAC: Service and Repair

Condenser Replacement

Tools Required

* J38185 Hose Clamp Pliers
* J39400-A Halogen Leak Detector

Removal Procedure

1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging.
2. Drain the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac-N-Fill).
3. Remove the cooling fans with the cooling fan shroud.




4. Reposition the radiator outlet hose clamp at the water pump housing using the J38185.
5. Disconnect the radiator outlet hose from the water pump housing.
6. Reposition the radiator outlet hose clamp at the radiator using the J38185.
7. Disconnect the radiator outlet hose from the radiator.
8. Remove the radiator outlet hose.
9. Disconnect the lower TOC line from the radiator.




10. Remove the A/C discharge hose nut from the condenser block.
11. Disconnect the A/C discharge hose from the condenser block.

Important: Cap or tape off the open A/C refrigerant components immediately to prevent system contamination.

12. Cap or tape off the A/C discharge hose.




13. Remove the evaporator inlet tube bolt from the condenser block.
14. Disconnect the evaporator inlet tube from the condenser block.
15. Cap or tape off the evaporator inlet tube.
16. Remove the radiator and condenser assembly.
17. Remove the condenser tube clip bolt.
18. Remove the condenser tube clip.




19. Remove the condenser mounting bolts.
20. Remove the condenser from the radiator.




21. Remove the receiver dehydrator upper bracket bolt.
22. Remove the receiver dehydrator lower mounting bolts.
23. Disconnect the receiver dehydrator from the condenser.
24. Remove and discard the sealing washers.

Installation Procedure

1. If replacing the condenser add the specified amount of PAG oil directly to the condenser. Refer to Refrigerant System Capacities.
2. Install new sealing washers to the receiver dehydrator.




3. Connect the receiver dehydrator to the condenser.

Notice: Refer to Fastener Notice.

4. Install the receiver dehydrator lower mounting bolts.

Tighten the bolts to 6 N.m (53 lb in).

5. Install the receiver dehydrator upper bracket bolt.

Tighten the bolt to 6 N.m (53 lb in).

6. Install the condenser to the radiator.




7. Install the condenser mounting bolts.

Tighten the bolts to 6 N.m (53 lb in).

8. Install the condenser tube clip.
9. Install the condenser tube clip bolt.

Tighten the bolt to 2.5 N.m (22 lb in).

10. Install the radiator and condenser assembly.
11. Remove cap or tape from the evaporator inlet tube.
12. Install a new sealing washer to the evaporator inlet tube fitting.




13. Install the evaporator inlet tube and bolt to the condenser block.

Tighten the bolt to 16 N.m (12 lb ft).

14. Remove cap or tape from the A/C discharge hose.
15. Install a new sealing washer to the A/C discharge hose fitting.




16. Install the A/C discharge hose and nut to the condenser block.

Tighten the nut to 16 N.m (12 lb ft).

17. Connect the lower TOC line to the radiator.




18. Install the radiator outlet hose.
19. Connect the radiator outlet hose to the radiator.
20. Reposition the radiator outlet hose clamp at the radiator to secure the hose using the J38185.
21. Connect the radiator outlet hose to the water pump housing.
22. Reposition the radiator outlet hose clamp at the water pump housing to secure the hose using the J38185.
23. Install the cooling fans with the cooling fan shroud.
24. Fill the cooling system. Refer to Draining and Filling Cooling System (Static Fill) Draining and Filling Cooling System (Vac-N-Fill).
25. Evacuate and recharge the A/C system. Refer to Refrigerant Recovery and Recharging.
26. Leak test the fittings of the component using J39400-A.