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.

CAUTION: Before removing the A/C condenser, note the location of each of the radiator/condenser air seals. These air seals are used to direct air through the A/C condenser and radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system.

A/C Condenser - Typical:

3. Remove the nuts that secure the discharge and liquid lines to the condenser tapping block (A/C Condenser - Typical).
4. Disconnect the discharge and liquid lines from the A/C condenser and remove and discard the O-ring seals.
5. Install plugs in, or tape over all of the opened refrigerant line fittings and condenser ports.
6. Remove the grille.
7. Remove the upper radiator crossmember.
8. Remove the bolts that secure the top of the grille opening reinforcement to the body to gain clearance for condenser removal.
9. If equipped with the 2.8L diesel engine, remove the condenser fan assembly.
10. If equipped, disconnect the transmission cooler lines from the automatic transmission cooler.
11. Remove the two bolts that secure the upper A/C condenser brackets to the radiator.
12. Lift the A/C condenser straight up and disconnect the lower brackets from the radiator.
13. Remove the A/C condenser from the engine compartment.

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. Carefully position the A/C condenser into the engine compartment.
2. Engage the lower condenser brackets to the radiator.
3. Install the two bolts that secure the upper condenser brackets to the radiator. Tighten the bolts to 5 N.m (44 in.lbs.).
4. If equipped, connect the transmission cooler lines from the automatic transmission cooler.
5. If equipped with the 2.8L diesel engine, install the condenser fan assembly.
6. Reposition the top of the grille opening reinforcement to the body and install the retaining bolts
7. Install the upper radiator crossmember.
8. Install the grille.
9. Remove the tape or plugs from the discharge and liquid line fittings and condenser ports.
10. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on 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.
11. Connect the A/C discharge and liquid lines to the A/C condenser and install the nuts. Tighten the nuts to 12 N.m (105 in.lbs.).
12. Reconnect the negative battery cable.
13. Evacuate the refrigerant system.
14. Charge the refrigerant system.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.

CAUTION: Before removing the A/C condenser, note the location of each of the radiator/condenser air seals. These air seals are used to direct air through the A/C condenser and radiator. The air seals must be reinstalled in their proper locations in order for the A/C and engine cooling systems to perform as designed.

1. Disconnect and isolate the negative battery cable.
2. Recover the refrigerant from the refrigerant system.

A/C Condenser - Typical:

3. Remove the nuts that secure the discharge and liquid lines to the condenser tapping block.
4. Disconnect the discharge and liquid lines from the A/C condenser and remove and discard the O-ring seals.
5. Install plugs in, or tape over all of the opened refrigerant line fittings and condenser ports.
6. Remove the upper radiator crossmember.
7. If equipped, remove the two bolts that secure the automatic transmission cooler to the radiator and position the transmission cooler aside.
8. Remove the two bolts that secure the upper A/C condenser brackets to the radiator.
9. Lift the A/C condenser straight up and disconnect the lower brackets from the radiator.
10. Remove the A/C condenser from the engine compartment.

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. Carefully position the A/C condenser into the engine compartment.
2. Engage the lower condenser brackets to the radiator.
3. Install the two bolts that secure the upper condenser brackets to the radiator. Tighten the bolts to 5 N.m (44 in.lbs.).
4. If equipped, position the automatic transmission cooler to the radiator and install the two retaining bolts. Tighten the bolts to 5 N.m (44 in.lbs.).
5. Install the upper radiator crossmember.
6. Remove the tape or plugs from the discharge and liquid line fittings and condenser ports.
7. Lubricate new rubber O-ring seals with clean refrigerant oil and install them on 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.
8. Install the discharge and liquid lines to the A/C condenser.
9. Install the nuts that secure the discharge and liquid lines to the A/C condenser. Tighten the nuts to 12 N.m (105 in.lbs.).
10. Reconnect the negative battery cable.
11. Evacuate the refrigerant system.
12. Charge the refrigerant system.