Condenser HVAC: Service and Repair

CONDENSER REPLACEMENT

REMOVAL PROCEDURE




1. Recover the refrigerant. Refer to Refrigerant Recovery and RechargingService and Repair
2. Remove the upper radiator support.
3. Remove the front evaporator tube to condenser retaining bolt.

IMPORTANT: Cap or tape the open evaporator tube and the condenser immediately to prevent contamination.

4. Disconnect the front evaporator tube from the condenser, discard the O-ring
5. Reposition the front evaporator tube.




6. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle

IMPORTANT: Prior to removal, take note of the compressor hose routing and orientation between the compressor and condenser.

7. Using a back-up wrench on the condenser fitting (2), loosen the compressor hose fitting (1) from the condenser.

IMPORTANT: Cap or tape the open compressor hose and the condenser immediately to prevent contamination.




8. Disconnect the compressor hose from the condenser, discard the O-ring.




9. Lower the vehicle; leaving the vehicle on the hoist.
10. Carefully raise the condenser along the radiator just enough to release the condenser tabs (1) from the radiator slots (2) and the condenser tube from the tube retainer (3).




11. Carefully separate the condenser from the radiator.




12. Remove the condenser from the vehicle.
13. Inspect the condenser insulators along the LH and RH front edges of the condenser for wear or damage.

INSTALLATION PROCEDURE




1. Replacement condenser will come without refrigerant oil.
2. If installing a replacement condenser, add 30 ml (1 oz) of refrigerant oil in the condenser.




3. Replace the condenser insulators (2), if necessary:
3.1. Remove all traces of the old insulators.
3.2. Using isopropyl alcohol, or equivalent, wipe clean the front surface of the condenser LH and RH edges.
3.3. Remove the paper backing (1) from the new insulators (2).
3.4. Align and install the insulators (2) while keeping a gap (3) of 1 mm (0.039 in) between the insulators (2) and the inner edges of the condenser, as shown.




4. Position the condenser into the vehicle.




5. Carefully join the condenser to the radiator so that the condenser is above the installed position.




6. Carefully lower the condenser along the radiator to secure the condenser tabs (1) to the radiator slots (2) and the condenser tube to the tube retainer (3).




7. Raise the vehicle.
8. Route the compressor hose to the condenser as noted prior to removal.
9. Remove the cap or tape from the compressor hose and the condenser.
10. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the compressor hose and the condenser.
11. Lightly coat the new O-ring (1) with mineral base 525 viscosity refrigerant oil.

IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the O-ring seal to enter the refrigerant system.

12. Carefully slide the new O-ring seal (1) onto the compressor hose until seated.




13. Install the compressor hose to the condenser.
14. Align the compressor hose to the condenser as noted prior to removal.

NOTE: Refer to Fastener Notice




15. Using a back-up wrench on the condenser fining (2), secure the compressor hose fining (1) to the condenser.

Tighten
Tighten the compressor hose fitting to the condenser to 24 N.m (17 lb ft).

16. Lower the vehicle.




17. Remove the cap or tape from the front evaporator tube and the condenser.
18. Using a lint-free clean, dry cloth, carefully clean the sealing surfaces of the evaporator tube and the condenser.
19. Lightly coat the new O-ring seal (1) with mineral base 525 viscosity refrigerant oil.

IMPORTANT: DO NOT allow any of the mineral base 525 viscosity refrigerant oil on the O-ring seal to enter the refrigerant system.

20. Carefully slide the new O-ring seal (1) onto the front evaporator tube until seated.

Leave a light coating of the refrigerant oil to remain on the evaporator tube in the area indicated (2) ONLY.




21. Install the front evaporator tube to the condenser.
22. Install the evaporator tube to condenser retaining bolt.

Tighten
Tighten the evaporator tube to condenser retaining bolt to 27 N.m (20 lb ft).

23. Install the upper radiator support.
24. Evacuate and charge the refrigerant system. Refer to Refrigerant Recovery and RechargingService and Repair
25. Check the condenser joints for leaks. Refer to Leak TestingLeak Testing