Condenser HVAC: Service and Repair

CONDENSER REPLACEMENT

Tools Required
J 39400-A Halogen Leak Detector

Removal Procedure
1. Recover the refrigerant.
2. Drain the engine Coolant.





3. Lift the locking lever on the mass air flow (MAF) sensor, then disconnect the MAF sensor electrical connector (1).
4. Lift the locking lever on the intake air temperature (IAT) sensor, then disconnect the IAT sensor electrical connector (2).
5. Loosen the two intake duct clamps (3). then remove the duct.
6. Remove the upper radiator hose from the radiator.
7. Remove the cooling fan and shroud.
8. Release the A/C compressor line retaining clip on the left side of the radiator.
9. Remove the A/C compressor line nut from the condenser and position the A/C compressor line aside.
10. Remove and discard the O-ring seals.
11. Remove the A/C receiver dehydrator.





12. Release the two condenser-to-radiator retaining clips as follows:
12.1. Press down on the 1st locking tab (1) while lifting on the condenser assembly.
12.2. Press down on the 2nd locking tab while lifting on the condenser assembly, then slightly pull the condenser assembly forward to clear the radiator mounting lugs.





13. Remove the two radiator upper mounting brackets (1).
14. Lift the radiator assembly upwards and lean the top of the radiator back.
15. Remove the condenser from the vehicle.

Installation Procedure
1. If replacing the condenser, add refrigerant oil to the condenser.
2. Install the condenser to the vehicle.
3. Lower the radiator into the lower insulators.





4. Install the two radiator upper mounting brackets (1).





5. Install the two condenser-to-radiator retaining clips as follows:
5.1. Slightly pull the condenser assembly forward to clear the radiator mounting lugs.
5.2. Ensure both locking tabs (1) are seated.
6. Install a new O-ring seal onto the A/C compressor hose.
7. Install new O-ring seals onto the receiver dehydrator tubes.
8. Install the A/C receiver dehydrator.
9. Install the A/C compressor hose to the condenser.

NOTICE: Refer to Fastener Notice in Service Precautions.

10. Install the A/C compressor hose block fitting nut to the condenser.

Tighten
Tighten the nut to 10.5 N.m (93 Ib in).

11. Install the retaining clip to the A/C compressor line on the left side of the radiator.
12 Install the cooling fan and shroud.
13. Install the upper radiator hose to the radiator.
14. Position the intake duct then install two intake duct clamps (3).





15. Connect the IAT sensor electrical connector (2).
16. Connect the MAF sensor electrical connector (1).
17. Fill the engine cooling system.
18. Evacuate and recharge the A/C system.
19. Leak test the fittings of the component using J 39400-A.