Condenser HVAC: Service and Repair

REMOVAL

WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION.

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

1. Recover the refrigerant from the refrigerant system .
2. Remove the front fascia.
3. Remove the four radiator sight shield retaining pins and the radiator sight shield

Radiator Air Seals:

4. Remove the radiator air seal retaining pins and the air seals.
5. Note the hood latch location on the upper radiator crossmember Mark the location of latch for reinstallation
6. Remove the two bolts that secure the hood latch to the upper radiator crossmember and position the latch out of the way
7. Remove the four transmission oil cooler mounting bolts and position the transmission cooler out of the way.

Condenser Lines:

8. Remove the nut that secures the discharge line fitting to the condenser inlet port on the right side of condenser.
9. Disconnect the discharge line fitting from the condenser inlet port
10. Remove the seal from the discharge line fitting and discard
11. Install plug in, or tape over the opened discharge line fitting and the condenser inlet port
12. Remove the nut that secures the liquid line fitting to the condenser outlet port on the right side of the condenser
13. Disconnect the liquid line fitting from the condenser outlet port
14. Remove the seal from the liquid line fitting and discard
15. Install plug in, or tape over the opened liquid line fitting and the condenser outlet port
16. Remove the two upper condenser mounting bolts
17. Lift the condenser up to disengage the lower condenser mounting brackets from the radiator
18. Remove the condenser from the vehicle

INSTALLATION

NOTE:
- If the condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system Use only refrigerant oil of the type recommended for the compressor in the vehicle
- 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 air conditioning and engine cooling systems to perform as designed

1. Position the condenser onto the vehicle
2. Engage the lower condenser mounts to the mounting brackets.
3. Install the upper condenser mounting bracket bolts. Tighten the bolts to 5 Nm (45 in. lbs.).
4. Remove the tape or plug from the condenser outlet port and the liquid line fitting.
5. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the liquid line fitting.
6. Reconnect the liquid line fitting to the condenser outlet port on the right side of the condenser.
7. Install and tighten the nut that secures the liquid line fitting to the condenser outlet port. Tighten the nut to 23 Nm (17 ft. lbs.).
8. Remove the tape or plug from the condenser inlet port and the discharge line fitting.
9. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the discharge line fitting.
10. Reconnect the discharge line fitting to the condenser inlet port on the right side of the condenser.
11. Install and tighten the nut that secures the discharge line fitting to the condenser inlet port. Tighten the nut to 23 Nm (17 ft. lbs.).
12. Position the transmission oil cooler onto the mounting brackets and install the four mounting bolts. Tighten the bolts to 5 Nm (45 in. lbs.).
13. Reposition the hood latch to the front of the upper radiator crossmember.
14. 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 14 Nm (123 in. lbs.).
15. Install the radiator air seals and the air seal retaining pins.
16. Install the radiator sight shield and the sight shield retaining pins.
17. Install the front fascia.
18. Evacuate the refrigerant system.
19. Charge the refrigerant system.