Condenser HVAC: Service and Repair

The condenser is located in front of the engine radiator and is integral to the cooling module. The condenser cannot be repaired and, if faulty or damaged, it must be replaced. An air seal on each side of the cooling module is secured to the condenser using plastic mounting rod with locking button fasteners, which cannot be reused. Six replacement fasteners are supplied with new condensers for reinstalling the air seals.

WARNING: REVIEW THE WARNINGS AND CAUTIONS BEFORE PERFORMING THE FOLLOWING OPERATION.

REMOVAL
1. Recover the refrigerant from the refrigerant system. Refer to Refrigerant Recovery for the proper procedures.
2. Disconnect and isolate the battery negative cable.

Fig.47 A/C Refrigerant Lines - Condenser:

3. Remove the nut that secures the discharge line fitting to the inlet fitting (upper fitting) of the condenser.
4. Disconnect the discharge line fitting from the condenser inlet fitting.
5. Remove the rubber O-ring seal from the refrigerant line fitting of the discharge line and discard.
6. Install plugs in, or tape over the opened condenser inlet fitting and the refrigerant line fitting of the discharge line.
7. Remove the nut that secures the liquid line fitting to the outlet fitting of the condenser.
8. Disconnect the liquid line fitting from the condenser outlet fitting.
9. Remove the rubber O-ring seal from the refrigerant line fitting of the liquid line and discard.
10. Install plugs in, or tape over the opened condenser outlet fitting and the refrigerant line fitting of the liquid line.
11. Remove the cooling module from the vehicle.

Fig.48 Condenser Air Seals:

12. From the front of the cooling module, disengage the tabs of the lower air seal from the slot at the bottom of each side air seal.

Fig.49 Condenser Remove/Install:

13. From the back of the cooling module, remove the four screws (two on each side) that secure the condenser to the radiator supports.
14. Remove the condenser from the cooling module.
15. Using a pair of side cutters, carefully cut the locking buttons off of the six (three on each side) mounting rods that secure an air seal to each side of he condenser.
16. Remove the side air seals from the condenser.

INSTALLATION
1. Position the side air seals onto the condenser.

Fig.50 Air Seal Mounting Rod:

2. Insert a new mounting rod with a foam pad through the condenser fins from the rear of the condenser and through the mounting hole in the side air shield. Then secure the air seal to the mounting rod by snapping a locking button over the end of the mounting rod from the front of the condenser. Repeat this procedure until each air seal is secured by three mounting rods with locking buttons.
3. Position the condenser onto the cooling module.
4. From the back of the cooling module, install and tighten the four screws that secure the con- denser to the radiator supports.Tighten the screws to 7.9 Nm (70 in. lbs.).
5. From the front of the cooling module, engage the tabs of the lower air seal with the slot at the bottom of each side air seal.
6. Reinstall the cooling module into the vehicle.
7. Remove the tape or plugs from the condenser outlet fitting and the refrigerant line fitting of the liquid line.
8. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the refrigerant line fitting of the liquid line. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle.
9. Reconnect the liquid line fitting to the condenser outlet fitting (lower fitting).
10. Install and tighten the nut that secures the liquid line fitting to the condenser outlet fitting. Tighten the nut to 27.7 Nm (245 in. lbs.).
11. Remove the tape or plugs from the condenser inlet fitting and the refrigerant line fitting of the discharge line.
12. Lubricate a new rubber O-ring seal with clean refrigerant oil and install it on the refrigerant line fitting of the discharge line. Use only the specified O-rings as they are made of a special material for the R-134a system. Use only refrigerant oil of the type recommended for the compressor in the vehicle.
13. Reconnect the discharge line fitting to the condenser inlet fitting.
14. Install and tighten the nut that secures the discharge line fitting to the condenser inlet fitting.Tighten the nut to 27.7 Nm (245 in. lbs.).
15. Reconnect the battery negative cable.
16. Evacuate the refrigerant system. Refer to Refrigerant System Evacuate for the proper procedures.

NOTE: If the condenser is 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.

17. Charge the refrigerant system. Refer to Refrigerant System Charge for the proper procedures.