Condenser Replacement

CONDENSER REPLACEMENT

REMOVAL PROCEDURE

TOOLS REQUIRED
J 39500-B A/C Refrigerant Recovery, Recycling and Recharging (ACR4) System




1. Recover the refrigerant from the A/C system. Refer to Refrigerant Recovery and Recharging. Service and Repair

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 lower hood latch support bolts (1).




10. Remove the fasteners (1) from the left and right sides of the front fascia support.
11. Lift and pull forward on the headlamp and bumper fascia support to obtain access to the condenser mounting bolts.

IMPORTANT: 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.

12. Remove the two condenser to radiator mounting bolts.
13. Separate the condenser from the radiator by lifting out of the lower mounting tabs.




14. Remove the two A/C condenser seals (1).
15. Lift the condenser up and remove from the vehicle.

INSTALLATION PROCEDURE

TOOLS REQUIRED
J 39400-A Electronic Halogen Leak Detector




1. Fill the new condenser with the proper amount of refrigerant oil. Refer to Refrigerant Oil Distribution. Service and Repair
2. Position the condenser into the vehicle.
3. Install the condenser into the lower radiator mounting tabs.

NOTE: Refer to Fastener Notice in Service Precautions.

IMPORTANT: 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

4. Install the condenser mounting bolts.

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

5. Install the new A/C condenser seals (1).




6. Reposition the headlamp and bumper fascia support and install the fasteners (1).

Tighten
Tighten the bolt and nut to 9 N.m (80 lb in).




7. Install the lower hood latch support bolts (1).

Tighten
Tighten the bolts to 9 N.m (80 lb in).

IMPORTANT: Inspect the seal washers for damage before reinstalling the A/C lines and hoses.

If any damage is noted during inspection, the suspect seal must be replaced.

Flat washer type seals do not require lubrication.




8. Install the evaporator hose to condenser.

Tighten
Tighten the nut to 20 N.m (12 lb ft).




9. Install the compressor hose to the condenser.

Tighten
Tighten the nut to 20 N.m (15 lb ft).




10. Install the upper radiator mounting brackets and bolts.

Tighten
Tighten the bolts to 9 N.m (7 lb ft).




11. Install the upper radiator seal.
12. Install the headlamp and bumper fascia mounting panel support bracket bolts.

Tighten
Tighten the bolts to 9 N.m (80 lb in).

13. Install the front headlamps.
14. Recharge the A/C system. Refer to Refrigerant Recovery and Recharging. Service and Repair

15. Test the A/C system for leaks using the J 39400-A. Refer to Leak Testing. Leak Testing