Condenser HVAC: Service and Repair

REMOVAL

WARNING:
- REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION.
- REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS GROUP BEFORE PERFORMING THE FOLLOWING OPERATION.

CAUTION: Before removing the condenser, note the location of each of the radiator and condenser air seals. These 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. Disconnect and isolate the battery negative cable.
2. Recover the refrigerant from the refrigerant system.
3. Remove the screws attaching the grille and headlamp mounting module to the upper crossmember of the vehicle. Refer to Body for this and further steps in the procedure.
4. Remove the headlamps from their mounts.
5. Remove the nuts that secure the hood latch and brace to the upper crossmember.
6. The radiator upper crossmember can be adjusted left or right through the use of its slotted mounting holes. Before removal, mark the original position of the crossmember.

Fig.6 Condenser Mounting - Typical:

7. Remove the bolts that secure the radiator to the upper crossmember and set it aside.
8. Remove the engine air filter inlet duct secured at the headlamp mounting module.
9. Remove the headlamp mounting module and front fascia for access to the condenser and fittings.
10. Disconnect the discharge line and liquid line refrigerant line fittings from the condenser. Install plugs in, or tape over all of the opened refrigerant line fittings.
11. Remove the bolts that secure the upper condenser and transmission cooler.
12. Carefully lift the condenser out of the vehicle.

INSTALLATION

WARNING: REVIEW THE WARNINGS AND CAUTIONS IN THE FRONT OF THIS SECTION BEFORE PERFORMING THE FOLLOWING OPERATION.

Any kinks or sharp bends in the refrigerant plumbing will reduce the capacity of the entire air conditioning system. Kinks and sharp bends reduce the flow of refrigerant in the system. A good rule for the flexible hose refrigerant lines is to keep the radius of all bends at least ten times the diameter of the hose. In addition, the flexible hose refrigerant lines should be routed so they are at least 80 millimeters (3 inches) from the exhaust manifold.

High pressures are produced in the refrigerant system when the air conditioning compressor is operating. Extreme care must be exercised to make sure that each of the refrigerant system connections is pressure-tight and leak free. It is a good practice to inspect all flexible hose refrigerant lines at least once a year to make sure they are in good condition and properly routed.

CAUTION: Before removing the condenser, note the location of each of the radiator and condenser air seals. These 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. Carefully position the condenser in the vehicle.
2. Install the bolts that secure the upper condenser and transmission cooler.
3. Remove the tape or plugs from the refrigerant line fittings on the condenser inlet and the discharge line. Connect the discharge line to the condenser inlet. Tighten the retaining nut to 28 Nm (250 in. lbs.).
4. Remove the tape or plugs from the refrigerant line fittings on the condenser outlet and the liquid line. Connect the liquid line to the condenser outlet. Tighten the retaining nut to 28 Nm (250 in. lbs.).
5. Install the headlamp mounting module and front fascia. Refer to Body for the procedure.
6. Install the engine air filter inlet duct.
7. Install the bolts that secure the radiator to the upper crossmember.
8. Install the nuts that secure the hood latch and brace to the upper crossmember.
9. Install the headlamps in their mounts.
10. Install the screws attaching the grille and headlamp mounting module to the upper crossmember of the vehicle. Refer to Body for this and further steps in the procedure.
11. Evacuate and Recharge the refrigerant system.
12. Connect the battery negative cable.

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.