Condenser HVAC: Service and Repair
CONDENSER REPLACEMENTTOOLS REQUIRED
J 39400-A Halogen Leak Detector
REMOVAL PROCEDURE
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging
2. Remove the upper tie bar support brace bolts at the upper tie bar.
3. Loosen the support brace bolts at the headlamp and bumper fascia mounting panel and position out of the way.
4. Remove the upper radiator seal.
5. Remove the upper radiator mounting brackets.
6. Disconnect the compressor hose from the condenser.
7. Remove the front headlamps.
8. Disconnect the evaporator hose from the condenser.
9. Remove the fasteners (1) from the left and right sides of the headlamp and bumper fascia mounting panel.
10. Lift the headlamp and bumper fascia mounting panel and pull forward in car to obtain access to the condenser mounting bolts.
NOTE: The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.
11. Remove the two condenser to radiator mounting bolts.
12. Separate the condenser from the radiator by lifting out of the lower mounting tabs.
13. Disconnect and remove the coolant sensor. (RPO UB7 only.)
14. Remove the two A/C condenser seals (1).
15. Lift the condenser up and remove from the vehicle.
INSTALLATION PROCEDURE
1. Add the proper amount of refrigerant oil to the new condenser; Refer to Refrigerant System Capacities.
2. Position the condenser into the vehicle.
3. Install and connect the low coolant sensor and wiring harness.
4. Install the condenser into the lower radiator mounting tabs.
NOTE:
^ Refer to Fastener Notice in Service Precautions.
^ The bolt retaining the condenser to the radiator end tank is a special length and should be the ONLY bolt used upon reinstallation. The use of a longer bolt will damage the radiator end tank.
5. Install the condenser mounting bolts.
Tighten
Tighten the connections to 6 N.m (53 lb in).
6. Install the new A/C condenser seals (1).
7. Reposition the headlamp and bumper fascia mounting panel and install the fasteners (1).
Tighten
Tighten the nut and bolt to 9 N.m (7 lb ft).
8. Install new seat washers.
9. Install the evaporator hose and nut to the condenser.
Tighten
Tighten the nut to 20 N.m (15 lb ft).
10. Install the compressor hose and nut to the condenser.
Tighten
Tighten the nut to 20 N.m (15 lb ft).
11. Install the upper radiator mounting brackets and bolts.
Tighten
Tighten the bolts to 9 N.m (7 lb ft).
12. Install the upper radiator seal.
13. Install the front fascia to tie bar support brackets and bolts.
Tighten
Tighten the bolts to 9 N.m (7 lb ft).
14. Install the front headlamps.
15. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging
16. Test the A/C system for leaks using the J 39400-A. Refer to Leak Testing.