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.

Radiator Air Seals:

2. Remove the two large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember.
3. Remove the five small screws that secure the front fascia grille inserts to the radiator sight shield.
4. Remove the radiator sight shield from the radiator closure panel crossmember.
5. Remove the two screws that secure the hood latch unit to the front of the radiator closure panel crossmember and move the latch out of the way over the top of the crossmember. Mark the location of latch for reinstallation.
6. Disconnect the hoses from the transmission oil cooler fittings on the left side of the cooling module.
7. Remove the nut that secures the discharge line fitting to the A/C condenser on the right side of the cooling module.
8. Disconnect the discharge line fitting from the condenser inlet port.
9. Remove the O-ring seal and gasket from the discharge line fitting and discard.
10. Install plugs in, or tape over the opened discharge line fitting and the condenser inlet port.
11. Remove the nut that secures the liquid line fitting to the condenser on the right side of the cooling module.
12. Disconnect the liquid line fitting from the condenser outlet port.
13. Remove the O-ring seal and gasket from the liquid line fitting and discard.
14. Install plugs in, or tape over the opened liquid line fitting and the condenser outlet port.

A/C Condenser:

15. Remove the screw that secures the top of the mounting bracket on each side of the condenser to the cooling module.
16. Lift the condenser, transmission oil cooler, and mounting brackets as a unit far enough to disengage the locating pin that secures the mounting brackets in the lower mount rubber isolators on each side of the cooling module.
17. Remove the condenser, transmission oil cooler, and mounting brackets from the vehicle as a unit.
18. Remove the two screws that secure each mounting bracket to the sides of the A/C condenser.
19. Remove the one screw that secures the left mounting bracket to the side of the transmission oil cooler.
20. Remove the left mounting bracket from the side of the condenser and transmission oil cooler.
21. Remove the condenser from the right mounting bracket and transmission oil cooler unit.

INSTALLATION

NOTE:
- If the A/C condenser is being replaced, add 50 milliliters (1.8 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 A/C condenser to the right mounting bracket and transmission oil cooler unit.
2. Position the left mounting bracket onto the side of the condenser and transmission oil cooler.
3. Install the screw that secures the left mounting bracket to the side of the transmission oil cooler. Tighten the screw to 5 Nm (45 in. lbs.).
4. Install the two screws that secure each mounting bracket to the sides of the condenser. Tighten the screws to 5 Nm (45 in. lbs.).
5. Position the condenser, transmission oil cooler, and mounting brackets into the vehicle as a unit. Be certain that the locating pins that secure the mounting brackets are engaged in the lower mount rubber isolators on each side of the cooling module.

NOTE: Verify that the condenser isolators are all installed and positioned correctly.

6. Install the two screws that secure the top of the mounting bracket on each side of the condenser to the cooling module. Tighten the screws to 5 Nm (45 in. lbs.).
7. Remove the tape or plugs from the condenser outlet port and the liquid line fitting.
8. Lubricate a new rubber 0-ring seal with clean refrigerant oil and install it on the liquid line fitting.
9. Install a new dual plan seal and reconnect the liquid line fitting to the condenser outlet port on the right side of the cooling module.
10. Install the nut that secures the liquid line fitting to the condenser. Tighten the nut to 23 Nm (17 ft. lbs.).
11. Remove the tape or plugs from the condenser inlet port and the discharge line fitting.
12. Lubricate a new rubber 0-ring seal with clean refrigerant oil and install it on the discharge line fitting.
13. Install a new dual plan seal and reconnect the discharge line fitting to the condenser inlet port on the right side of the cooling module.
14. Install the nut that secures the discharge line fitting to the condenser. Tighten the nut to 23 Nm (17 ft. lbs.).
15. Reconnect the hoses to the transmission oil cooler fittings on the left side of the cooling module.
16. Reposition the hood latch unit to the front of the radiator closure panel crossmember.
17. Install the two screws that secure the hood latch unit to the front of the radiator closure panel crossmember. Check and adjust the hood latch as needed. Tighten the screws to 14 Nm (123 in. lbs.).
18. Position the radiator sight shield onto the radiator closure panel crossmember.
19. Install the five small screws that secure the front fascia grille inserts to the radiator sight shield. Tighten the screws to 2 Nm (17 in. lbs.).
20. Install the two large screws that secure the front fascia and the outboard ends of the radiator sight shield to the radiator closure panel crossmember. Tighten the screws to 6 Nm (53 in. lbs.).
21. Evacuate the refrigerant system.
22. Charge the refrigerant system.