Condenser Replacement
Replacement condenser assemblies are direct replacements for the existing condensers and are used as follows:1985-1986 On all Engines, 52450904 condenser replaces 3057628 condenser.
1987-1988 52450903 condenser replaces 3091057 condenser on LB4 engines (gas V6, 4.3L); L03 engines (gas V8 5.0L); L05 engines (gas V8, 5.7L).
52450904 condenser replaces 3057628 condenser on LH6 engines (diesel 8 cylinder, 6.2L); LL4 engines (diesel 8 cylinder 6.2L heavy duty); and LT9 engines (gas V8 heavy duty 5.7L (350).
SERVICE PROCEDURES
I. CONDENSER REPLACEMENT
Follow procedure described in Section 1B of the G Van Service Manual.
Labor Op D3140 Time: .7 hr Gas .6 hr Diesel
Add: .3 hr with auxiliary oil cooler
Add: .5 hr - discharge/ charge A/C system
FIGURE 1:
II. HEATER WATER BY-PASS VALVE INSTALLATION (Figure No. 1)
a) Drain radiator
b) Remove air cleaner inlet tube.
c) Remove heater hose (1) and discard
d) Remove beater hose (2) from heater core and install at inlet connection of heater water by-pass valve (3) and tighten hose clamp (4).
NOTICE: All hose clamps removed during valve installation should be discarded and replaced with new hose clamps.
e) Install new 5/8" performed heater hose
(5) from heater by-pass valve to heater core (cut to length).
f) Install new 3/4" performed heater hose
(6) from heater water by-pass valve to heater core (cut to length).
g) Install new 3/4" preformed heater outlet hose (1) from heater water by-pass valve to radiator (cut to length).
b) Wrap plastic wiring harness around heater hose (1) to eliminate kinking and chafing.
i) Band strap beater hose (2) to beater hose (1) as shown so hoses do not rub edge of radiator shroud.
j) Tighten all hose clamps.
FIGURE 2:
FIGURE 3:
FIGURE 4:
IIA. VACUUM VALVE INSTALLATION (Figures No. 2,3, and 4)
a) Drill a 7/32", diameter hole in dash wall next to hood latch cable (Figure No. 2) and deburr edges of hole.
b) Install vacuum hose (1) on heater water by-pass valve (2) and route with A/C harness (3) to bole in dash. Band strap
(4) hose to harness as shown. Apply sealer around hose as necessary to seal.
c) Remove engine cover and instrument panel lower extension for next step.
d) Remove instrument cluster trim plate.
e) Remove HVAC control assembly (Figure No. 3) and slide assembly out of dash sufficiently to gain access to rear of the unit.
f Install vacuum valve on heater control
assembly (Figure No. 3). Slide one mounting ear on valve under the slot on control assembly. Install and tighten screw in opposite ear. (Note: Pin on bottom of vacuum valve must fit into slot on the temperature control arm.)
g) Locate gray colored vacuum source line at A/C control assembly (Figure No. 4).
h) Cut gray vacuum source line and insert vacuum tee (1) (Figure No. 4). Attach 6" long vacuum line from vacuum tee to vacuum valve inlet port 1. Attach vacuum hose from heater valve to vacuum valve outlet port 2 (Figure No. 4).
Notice: Port numbers are identified on valve.
i) Reinstall control assembly in dash.
j) Reinstall instrument cluster trim plate.
k) Reinstall engine cover and instrument panel lower extension.
l) Refill radiator with coolant.
m) Run engine and check for coolant leaks.
n) Place temperature control arm in high heat position, check the position of the lever on the heater water by-pass valve. It should be in the extended position. Place control selector in the full cold position and recheck valve. Lever should be in the retracted position.
o) Shut off engine and reinstall air cleaner inlet tube.
Labor Op: T7535 Labor Time: 1.3 hrs.
III. AIR INLET RECIRCULATING DOOR REPLACEMENT
A. Removal
1. Drain radiator
2. Disconnect battery ground cable.
3. Remove engine cover.
4. Remove steering column filler panel and remove panel.
5. Remove steering column support bracket and allow column to drop for clearance.
6. Remove right hand sunvisor.
7. Remove right hand pillar post molding (if so equipped).
8. Remove upper instrument panel support bracket.
9. Raise and support right side on instrument panel.
10. Remove R.H. heater duct.
11. Remove L.H. heater duct.
12. Remove recirculating air door actuator. Remove and rotate actuator to unhook actuator arm from valve.
13. Disconnect 2 heater cables and clamps and 4 vacuum hoses to heater and recirculating door actuators.
14. Remove front heater valve actuators and remove actuators.
15. Remove defroster duct to heater and lift duct.
16. Loosen clamps and disconnect beater inlet and outlet hoses.
17. Remove heater to cowl and remove heater from vehicle.
18. Remove air recirculating door to cowl.
19. Remove door and discard. Retain gasket.
B. Installation
1. Remove actuator from new door.
2. Install new door and gasket. Secure with 6 screws.
3. Reverse removal procedure.
Labor Op: T7540 Labor Time: 3.3 hrs.
FIGURE 5:
IV. EVAPORATOR CORE CASE SEAL REPLACEMENT (Figure No. 5)
a) Follow evaporator core replacement procedure found in Section 1B of the Service Manual.
Notice: Complete evaporator core removal is not required. Removal of the core case assembly will allow access to the seal.
Labor Op T7545 Labor Time: 1.0 hrs.
Add .5 hrs to dis-
charge/charge
A/C
Labor Op T7550 Labor Time: 5.8 hrs to per-
form all of the
above proce-
dures