Condenser HVAC: Service and Repair

REMOVAL

WARNING: REFER TO THE APPLICABLE WARNINGS AND CAUTIONS FOR THIS SYSTEM BEFORE PERFORMING THE FOLLOWING OPERATION. FAILURE TO FOLLOW THE WARNINGS AND CAUTIONS COULD RESULT IN POSSIBLE PERSONAL INJURY OR DEATH.




1. Recover the refrigerant from the refrigerant system.
2. Disconnect and isolate the negative battery cable.
3. Remove the push-pin retainers (1) and the upper condenser/radiator seal (2).




4. Disconnect the wire harness connectors from the condenser cooling fan motor (9) and the A/C pressure transducer (10).
5. Remove the two wire harness retainers (2) from the condenser fan shroud (4) and position the wire harness out of the way.
6. Remove the nuts (1 and 8) that secure the A/C discharge line (5) and A/C liquid line (7) to the A/C condenser (6).
7. Disconnect the A/C discharge and liquid lines from the A/C condenser and remove and discard the O-ring seals and gaskets.
8. Remove the A/C discharge line from the retainer (3) located on the condenser fan shroud (4).
9. Install plugs in, or tape over the opened discharge and liquid line fitting and condenser ports.




10. Remove the three bolts (1) that secure the upper radiator support (2) to the upper front crossmember (5).
11. Remove the upper radiator support and position the radiator overflow hose (3) out of the way.
12. Remove the bolt that secures the condenser/cooling fan assembly (4) to the upper left fender rail.
13. Carefully push back the radiator (6) for clearance and remove the condenser/cooling fan assembly from the engine compartment.




14. Place the condenser/cooling fan assembly on a workbench and remove the two screws (1) that secure the A/C condenser (2) to the condenser fan shroud (3).
15. Remove the A/C condenser from the condenser fan shroud.

INSTALLATION

NOTE: If the A/C condenser is being replaced, add 30 milliliters (1 fluid ounce) of refrigerant oil to the refrigerant system. Use only refrigerant oil of the type recommended for the A/C compressor in the vehicle.




1. Position the A/C condenser (2) into the condenser fan shroud (3).
2. Install the two bolts (1) that secure the A/C condenser to the condenser fan shroud. Tighten the bolts to 5 N.m (45 in. lbs.).




3. Carefully push back the radiator (6) for clearance and install the condenser/cooling fan assembly (4). Insert the two lower condenser fan shroud mounting tabs into the holes in the lower front cross member.
4. Install the bolt that secures the condenser/cooling fan assembly to the upper left fender rail. Tighten the bolt to 5 N.m (45 in. lbs.).
5. Position the radiator overflow hose (3) to it's installed location
6. Align the upper mounting tab of the condenser/ cooling fan assembly to the hole in the upper radiator support (2) and install the upper radiator support.
7. Install the three bolts (1) that secure the upper radiator support to the upper front crossmember (5). Tighten the bolts to 23 N.m (17 ft. lbs.).




8. Remove the tape or plugs from the discharge and liquid line fittings and condenser ports.
9. Lubricate new rubber O-ring seals with clean refrigerant oil and install them and new gaskets onto the discharge and liquid line fittings. 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 A/C compressor in the vehicle.
10. Connect the A/C discharge line (5) and the A/C liquid line (7) to the A/C condenser (6).
11. Install the nuts (1 and 8) that secure the A/C discharge and liquid lines to the A/C condenser. Tighten the nuts to 22 N.m (16 ft. lbs.).
12. Install the A/C discharge line into the retainer (3) located on the condenser fan shroud.
13. Install the wire harness and the two wire harness retainers (2) to the condenser fan shroud (4).
14. Connect the wire harness connectors to the condenser cooling fan motor (9) and the A/C pressure transducer (10).




15. Position the upper condenser/radiator seal and install the push-pin retainers.
16. Reconnect the negative battery cable.
17. Evacuate the refrigerant system.
18. Charge the refrigerant system.